When cutting sheets of plywood, it’s important to support the entire sheet to keep it from pinching the blade of the saw. Here’s how to modify sawhorses to safely support plywood while cutting with a circular saw.

  1. Make two 1½” deep cuts, spaced 1½” apart, at both ends of the top of each sawhorse.
  2. Use a hammer and chisel to remove the waste between the cuts, leaving two 1½” x 1½” notches in the top of each sawhorse.
  3. Place long pieces of 2” x 2” lumber in the notches between the two sawhorses, so they’re flush with the top of the sawhorses.
  4. Set the depth of the circular saw blade so it cuts through the plywood but not too deeply into the sawhorses or supports.
  5. Use the circular saw to rip or crosscut the plywood.

The combination of 2x2s supports and the top of the sawhorses creates a sturdy support for cutting plywood.

Watch the video above to find out more.

Further Information

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Joe Truini

Radio Show Co-Host

Joe Truini is a contractor, author, and the host of “Simple Solutions” on Today’s Homeowner TV and the weekly Today’s Homeowner radio show. He has worked on both large commercial projects and residential remodeling, and has written for national publications such as This Old House and Popular Mechanics. He has also written eight books, including three best-selling shed-building books. Joe lives in Connecticut with his family and enjoys hiking, traveling, and baseball in his spare time.

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