Brian’s Improved Saw Bench

Viewer Project - By Brian Tracey from Santa Fe, NM
Added on October 4, 2012

Whenever I tried to do rip cuts (by hand) on my Schwarz/ Pop Woodworking style Saw Bench, the saw would hit the splayed legs, so I would try to move the wood out further from the Bench Top and it always felt awkward and unbalanced. I got to thinkin…what if we could have a split top Saw Bench with no top connectors to have to avoid? This is what I came up with.
It’s made from milled HD construction grade mystery wood and some scraps of poplar. The key to the rigidity of the bench is the Draw Bored joints to the two bases. I did also add some holdfast holes in the top and blocks under the holes for a little added thickness where needed. This thing is rock solid and both rip and cross cuts are now a lot easier to control.

Discussion

Dean October 4, 2012 2:41 pm

Brian, I like your saw bench very much. I’ve thought of something similar, but I couldn’t figure out how to do it with just wood. The large dovetails are a nice touch, and along with the draw boring, it must help in keeping it rigid. Would you explain a little more about the holes and blocks in the top? Thanks for putting the idea together for me (and others). Now, if I could just figure out how to get you to mail me that beautiful hand saw! ;-)

Reply
Brian Tracey October 4, 2012 3:02 pm

Dean,
Sorry i can’t help you with the saw, It’s an old Disston D8 that I refurbished and re-worked (some would say…ruined) the handle on.
As far as the blocks and holes, I just drilled a few 3/4″ holes in the top to allow the use of holdfasts and added blocks underneath in the area of the holes to give some added thickness so that the holdfasts would hold better. The HD mystery lumber is pretty soft…like… somewhere between really soft pine and balsa! Even so this thing is still rock solid.
Brian

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Jay October 4, 2012 4:14 pm

I hope the Schwarz sees this and comments on it! I like how the top pieces are joined to add strength!

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Jon McGrath October 4, 2012 4:39 pm

Very cool. I have to admit I have exactly the same issues and in the middle of drawing out a more stable bench set up and will use some of your ideas. Good stuff.

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Claude Stewart October 4, 2012 5:48 pm

Looks like it will do the job.

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Bryce Sommerer October 4, 2012 7:21 pm

nice set up…very nice looking, I like the dove tails

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Joe October 5, 2012 12:14 am

So simple, so effective! My first improvement idea is to incorporate a storage for your rip saws into the saw bench.

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Joel October 5, 2012 8:00 am

Anyone who does rip cuts by hand impresses me. I don’t have that kind of energy or patience. Nice idea on the bench

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tom buhl October 5, 2012 8:27 am

and whoever can remove the saw from the board becomes the next king

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Dave October 5, 2012 9:05 am

I will definitely keep this design in mind when I build mine. Thanks for sharing.

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Charlie October 5, 2012 11:20 am

I am wanting/needing to build one of these but have not gotten to it as yet. I have seen Chris’ version but I like this version- think I will go with it! Thanks for sharing your design.

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Jim October 5, 2012 4:38 pm

I want to build one. How do I print the #$@!! pictures from this web site?
Looks like 2×6 lumber right? Are the foot pieces glued tx4s?

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- thewoodwhisperer October 5, 2012 7:04 pm
  
  The pictures are set to open in a gallery. So using the small thumbnails above, right-click and open in a new tab or a new window. That will will bring up the full size picture in it’s own space so you can save and print.
  
  Reply
  - Jim October 5, 2012 8:15 pm
    
    That worked, thanks. Right click on the thumbnail and select “Save Link As…”
    
    Reply
daniel drabek October 5, 2012 5:33 pm

Reminds me of the old days when they used to rip lumber in a saw-pit–but on a smaller scale. Not my idea of fun, but if you want to avoid using a table saw, it looks like it would work as well as anything.

DD

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Brian Tracey October 7, 2012 1:24 pm

Jim,
You’re correct the whole saw bench is made from HD 2X6’s and 2X4’s with some scrap 3/4″ poplar for the braces. The foot pieces are glued up 2X4’s. All of the lumber was milled down to just square.
The stability of this bench comes from the Draw Bored Mortice and Tenon connection of the foot pieces to the uprights.
Brian

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Phil Collins October 8, 2012 8:09 am

Simply neat……love it. Nice one Brian. : )

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Bob D. October 9, 2012 5:37 am

Excuse my ignorance but what is the advantage of using a small bench like this one instead of a big work bench?

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Brian Tracey October 9, 2012 7:55 am

Bob D.
The main purpose of a saw bench like this is to get the work down so that a person can use hand saws most efficiently. It puts the wood down around knee height so that you have a way to both hold the wood (with a knee) and cut the wood with a hand saw at the same time. They are used mostly for cross cutting and ripping. Joinery saws would mostly be used on the main workbench. I do use the saw bench with my jig saw as well.
Hope that helps.
Brian

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- Bob D. October 9, 2012 8:49 am
  
  I see, better posture for better accuracy.
  
  Thank you Brian.
  
  Reply
jim j October 10, 2012 7:22 am

Very innovative design, Brian.

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Martin Allison December 19, 2012 5:42 am

I liked your bench very much Brain. I was also facing the same problem while sawing wood. Good I found this post. I dint have the idea of building a bench, but though of buying one. But after seeing this post, I think it would be a better idea to build one. Keep up the good work.

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Steve November 15, 2013 10:34 am

I really want to build a saw bench like this. What are the dimensions? That would be so helpful.

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vera musso November 21, 2017 5:44 am

it’so beautiful

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Roger March 28, 2018 5:51 am

It is fun to note that after 6 years, ‘Brian’s Improved Sawbench’ sure has a presence on the internet. I’m just finishing up mine and it is looking to be as ‘rock solid’ as advertised. It is part of my Roubo workbench project in that as a beginner to hand woodworking I thought a bit of practice might take some of the stress of trying to do it right the first time out of the equation. Plus give me a place up off the floor to glue up the large top besides the floor. Paul Seller’s ‘Three Joints’ was very helpful though a couple of em are going to need epoxy. Anyhow, thanks to Brian for posting his project!

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Matthew Bain December 23, 2019 10:53 pm

Do you have any pictures or suggestions (ie I would love exact measurements) that you found best for the hold fast holes. I built my bench and even added extra an extra full length board (on both sides) to make the top boards 2.75” thick to accommodate the hold fasts (I started with 8/4 soft maple and ended up dimensioning lumber to 1.5” thickness). Every thing is ready except my courage to drill the holes for the hold fasts. Looking for some guidance to help build up the courage to drill holes in this function piece of art. Thanks for your help.

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Brian’s Improved Saw Bench

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