Building a Japanese Inspired Sawhorse

Why I Built Sawhorses Instead of a Coffee Table (And Why You Might Want To, Too)

When my wife asked me to build her a coffee table for the living room, I had a different idea—one that suited my woodworking style a little better. Instead of a traditional table, I decided to build a pair of sturdy sawhorses. Not only would they be more useful in the long run, but they’d also serve as a functional workspace for future projects.

The Design: Built for Work, Not Just Looks

These aren’t your average sawhorses. I designed them with a row of dog holes for planing stops and holdfasts, ensuring workpieces stay secure. The entire build relies on mortise-and-tenon joinery with wedges for maximum durability.

Originally, I chose hard maple for its toughness, which is ideal for job site abuse. But when it came time to hand-cut the joinery, I quickly realized just how hard maple is. Chiseling through it was a workout!

Layout and Cutting: Chalk, Bandsaws, and Templates

To maximize material efficiency, I did most of my layout in chalk, making it easy to adjust markings as needed. After rough-cutting the pieces, I squared everything up at the jointer and planer.

For the legs, I created a plywood template, cut it out on the bandsaw, and refined it with a spindle sander. Then, using a pattern bit with top and bottom bearings, I routed the legs to their final shape, always cutting with the grain to minimize tear-out.

Joinery: The Battle of Square vs. Round Tenons

The mortise-and-tenon joints were the heart of this build. I used a custom router jig to cut the mortises, then squared the corners with a mortise chisel—because, in my opinion, round tenons just look wrong. (Yes, I know some people love them. No, I will not be convinced otherwise.)

For extra strength, I added wedges to lock the tenons in place. To prevent splitting, I cut relief slots and drilled oversized holes at the base.

Assembly: Glue, Wedges, and a Little Force

Once everything was prepped, I glued the legs into the base, flipped them over, and hammered in the wedges to lock everything tight. The lower rails got the same treatment, with decorative wedges adding both function and style.

The Top: Dog Holes for Versatility

For the work surface, I drilled a combination of ¾-inch and ⅞-inch dog holes to accommodate both planing stops and holdfasts. After gluing the upper rail in place, I transferred the holes through it, ensuring full functionality.

Final Touches: Feet and Comfort

To prevent rocking on uneven ground, I added adjustable feet. Then, I rounded over the top edges for comfort—because even a workhorse should be pleasant to use.

Want to Build Your Own?

If you’re inspired to make a set, I’ve got plans available here. And if you do build them, tag me on Instagram—I’d love to see your version!

Now, if you’ll excuse me, I have to go explain to my wife why the living room has sawhorses instead of a custom coffee table. (Worth it.)

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