UPDATE: This setup served me well for about 6 months, but died this weekend. When assembled it is a really sturdy platform. Disassembled, the brackets are weak and prone to bending. During the assembly process they are easily damaged as well. I don’t regret having built it, but will be doing sheet goods differently in the future.
I will need a temporary work surface when renovating the new house, and have a lot of sheet goods and drywall to cut up. I thought about building some sawhorses and adding on to them, but I don’t have much time. Instead I started with two of these Burro branded horses. Honestly, for 20 bucks a piece, these things are pretty good. Made in USA, stackable, stable, and strong. Just make sure you are choosy, not all were created equal. Explaining the build will be easier with a before and after shot.
I want to put a full sheet of plywood or drywall on these and have the cuts be well supported. That would require a structure almost a full 4×8 feet. I used metal brackets to help it be a quick assemble and break down job. Two 42″ 2x4s go across the saw horses. The saddle brackets keep them upright and a right angle bracket on the edge holds a long support to tie the two horses together.
Every time I use these as a cutting surface I am going to cut into the 2x4s a little. I will adjust blade depth to minimize the damage, but I don’t want metal anywhere near the top surface. The brackets that hold my middle support were too tall, so I cut them down.
The table breaks down into 2 stackable horses, 2 supports that go on top of the horses, 2 long ones that go from horse to horse, and a center one to help prevent sag. The only extra screws needed for assembly are at the four corners where the long stretchers meet the supports on top of the horses. I made sure to install the screws low so the saw won’t catch them. The horses still stack, even with those saddle brackets installed.
When I assembled this I didn’t screw any of the 2x4s down to the horse’s saddle brackets. It all still felt stable. A half inch sheet of plywood and a few screws should turn it into a sturdy temporary work bench. All the drywall cutting I need to do will be aided by this big stable platform as well. The assembled dimensions of the top are 44×84″. Enough to support a 4×8′ sheet, but leave some room at the edges.
When the house work is done I will probably keep it as a way to break down sheet goods. This will be a big upgrade over my current method of hanging them out of the back of the suburban.