With all the leg frame glued, the protruding legs are cleanly cut and planed flush with the top surface of the cross beam. Then Paul moves onto the gussets which will help hold the legs rigid, and cuts them to size and shape. They are glued and screwed in place, then the bottoms of the legs are scribed and sawn to remove any unevenness.
In this first episode, Paul covers the stock used and gets going with the layout using a board to get the correct angles for the leg recess. Once the recesses are cut, Paul shows the method for laying out the compound angle using a scribe cut to get the correct splay, before cutting and fitting the joint. Then they can be glued and screwed into position.
Paul shows how to make a pair of sawhorses using the method he first learnt when he was 16. They are very useful around the shop for resawing stock and a many others uses. The sawhorses makes use of a compound housing joint that ensure a solid construction.