Step 1 Cut 1 end face of 1 leg at a 20° angle. Measure 765mm from long point of this cut to find short point of a second cut at the same angle. Make this cut
Step 2 At 1 end of leg, draw a square line across it 5mm from long point of angled cut. Cut off end up to this line. Repeat Steps 1 and 2 to make another leg.
Step 3 At shortened end of 1 leg, place a T-hinge so it’s centred on leg and flush with the end. Screw to leg. Make other leaf of hinge flush with shortened end of other leg. Ensure both legs will be in line when hinge is closed, then screw hinge to leg.
Step 4 Cut leg stay to length with angle grinder and round off corners. Mark centre of stay 12mm from each end. At these points, drill a 6mm hole in 1 end and a 9mm hole in the other. From larger hole, cut width of hole to 1 side to create a hook. Use a file to smooth edges.
Step 5 Position metal stay halfway up side of 1 leg. Using a 75mm batten screw with a washer behind it, screw through 6mm hole so it’s fixed to leg but can still move. Open legs and place a square on top so they’re in line. Swing stay to other leg and mark centre of hook. Screw an 8mm coach bolt into this point, leaving it out slightly so the hook can catch on it.
Step 6 Repeat Steps 1–5 to make another joined pair of legs.
Step 7 Join both pairs of legs with a cross rail fixed flush with sides and 225mm up from bottom. Make sure metal stays are on outside of this assembly.
Step 8 Place top on open legs so it’s centred and 1 end overhangs 1 pair of legs by 25mm. Mark a line 25mm from one side. Mark 45 and 85mm from end of top along this line. Screw top into 1 leg at these points with batten screws. Repeat to attach other pair of legs to top, screwing through the same side as the first. Repeat all steps to make another saw horse.