Saw Horse Panel Saw

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Project by SebringDon posted 09-29-2013 05:55 PM 4379 views 23 times favorited 11 comments Add to Favorites Watch

I wanted a safe and secure way to break down large sheets of plywood, but working from a one-car garage space is at a premium. When I saw this plan at Bob’s Plans (it’s free) I knew I’d found my solution. I made it all out of cutoffs from other projects, so the only cost was the hardware, basically some 5/16 bolts, nuts and washers, along with some furniture levelers. I even made my knobs from some scrap and t-nuts.

The first pic is a cheat from Bob’s Plans, since I forgot to take a pic of the basic setup. In the second and third pics you can see me set up to rip a full sheet of 3/4” plywood, and then crosscut the piece I ripped. The last two pictures show the “hard” part of the project, the upper clamps used to secure the plywood panel, and the lower clamps used to secure the rails to the two main supports. I think the plan only calls for four of each, but you’ll definitely need 8 of the lower clamps. I got by just fine on four of the upper clamps, though.

It fills up my carport quite nicely in use, but breaks down into a small package stored on top of a cabinet when not needed. Highly recommended if you want a simple system that doesn’t take up much room but still provides a rock-solid platform at a comfortable height.

As always, comments and suggestions for improvements appreciated.

-- Don

11 comments so far

View WayneC's profile


14358 posts in 4518 days

#1 posted 09-29-2013 05:56 PM

Very nice.

-- We must guard our enthusiasm as we would our life - James Krenov

View waho6o9's profile


8675 posts in 2997 days

#2 posted 09-29-2013 06:02 PM

Very innovative, great job Don.

View PaulLL's profile


160 posts in 2397 days

#3 posted 09-29-2013 06:21 PM

Thanks for sharing Don, I need something like this!

View scarpenter002's profile


617 posts in 4326 days

#4 posted 09-29-2013 09:39 PM

Looks like a nice addition to a small shop.
Thanks for sharing Don.

-- Scott in Texas

View mjrausch's profile


20 posts in 2276 days

#5 posted 09-29-2013 10:11 PM

got to think about doing this

-- mjrausch

View hoss12992's profile


4148 posts in 2313 days

#6 posted 09-30-2013 06:23 AM

This is really handy. Great job

-- The Old Rednek Workshop

View Holt's profile


280 posts in 3050 days

#7 posted 09-30-2013 04:01 PM

My saw table was pretty much rotted out and the banquet legs were pretty worn out, so I tossed the whole thing during our latest move. This look like a better idea for the replacement., Thanks for posting!

-- ...Specialization is for insects.

View helluvawreck's profile


32086 posts in 3287 days

#8 posted 09-30-2013 04:03 PM

That will be a nice addition to your shop. Congratulations.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View BBF's profile


144 posts in 2259 days

#9 posted 09-30-2013 04:57 PM

Thanks for sharing. I saw this and had to make one right away. I usually break down my panels in the barn and carry them back to the shop this now saves me that step.

-- I've never been disappointed buying quality but I have been disappointed buying good enough.

View RobWoodCutter's profile


116 posts in 3650 days

#10 posted 09-30-2013 05:03 PM

I have done similar but not with the detail you have done here. I use the same saw horse, put a sheet of OSB on top of them and then put a sheet of 1” rigid 48”x96” pink foam board on top. That way I use the foam as a disposable cutting surface under the board I am cutting. Now that I have a more permanent 4’x8’ assembly table, I just put the 1” foam on top of it when I need to cut down something with the track saw. The 1” foam pretty much stays on the table now, because I can drill/cut into it without damaging the main top, and it has two usable sides. It is also a soft surface to sit projects on without dinging and damaging a corner or edge.

-- Rob-Yorktown "Shop's still not done, Tools are bought, Wood is bought, need to find time to start a project.."

View bob62's profile


160 posts in 3038 days

#11 posted 09-30-2013 05:05 PM

This is amazing! I have cut a lot of plywood and tried many different ways and this jig really works! Thanks

-- Robert, Mississippi,

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