PHOTOS BY DAN CARY
ILLUSTRATIONS BY GABRIEL GRAPHICS
DESIGNS BY VERN GRASSEL, LARRY OKREND AND DAN CARY

Boasting that you built the best sawhorse is like claiming that your mom makes the best chocolate chip cookies - you're bound to hear some differing opinions. Even so, we're claiming bragging rights for a few blue-ribbon contenders.

In an attempt to create the best sawhorse ever, frequent contributor Vern Grassel, HANDY Editor Larry Okrend and I combined our 70-plus years of workshop experience in a brainstorming session. The results are featured in Workshop Sawhorses, (July/August 2007 HANDY, p.12).  In the process, we also designed this sawhorse-inspired tool tote. Think of it as a toolbox disguised as a sawhorse. It's just the right height to use as a stepstool or seat, and it works well for hauling small tools and materials.

Here's how to build the tool-toting sawhorse, in four steps:

1. Assemble the bin front, back, bottom, ends and long divider with 1-5/8-in. screws. Round over the top edges of the bin with a router and 1/8-in.-dia. roundover bit or with sandpaper. Cut a 36-in.-long piano hinge in half to create two 18-in. hinges. Position the hinges on the long divider so that the lids will lie flat on the bin when closed, and attach the hinges with the screws provided. Offset the hinges so that the screws from either side do not interfere with each other.

2. Attach the lids to the hinges. Drive two screws and test the fit before driving the rest of the screws.

3. Cut out the side panels. Attach them to the bin with four 1-5/8-in. screws. Use the same screws to attach the top to the sides and to fasten the brace to the top and sides.

4. Cut out the handle brackets. Bore 1-1/8-in.-dia. x 1/2-in.-deep recess holes for the handle in each side bracket. Drill 1/4-in. holes through the brackets and sides. Attach the handle between the brackets with glue and 1-5/8-in. screws. Align the holes in the brackets and sides and slide a 1/4 x 2-in. carriage bolt through the holes, fitting washers between the bracket and sides. Secure each bolt with a locknut.