Bora Speedhorse Metric Lumber Adapter

thingiverse

UPDATE 2020-07-08: A new version (v2) is now available, featuring a better design that allows room to flip up the leg release lever without obstruction and uses less material. The original version remains intact for those who prefer it. I recently acquired Bora Speedhorses and attempted to utilize the feature allowing lumber to be added to the top and sides of the sawhorses to create a material support. However, two significant issues arose. The first issue was that the Speedhorse is designed for USA 4x2 lumber, which is not available in Australia. Instead, metric lumber is used, typically either 35x70mm or 35x90mm, neither of which can be used on the Speedhorse so that the sides and tops align. To address this, I created a device that slides into the slots on the ends of the sawhorses to hold 35x70mm lumber snugly as well as at the perfect height for use with 35mm lumber on top. I may re-design this in the future since the adapter prevents the leg release levers from being pulled far enough to collapse the legs. To collapse the legs, it's necessary to slide the adapter up slightly, which is not a significant inconvenience but could be addressed through design changes. The second issue was that with lumber on top of the Speedhorse, it becomes impossible to grip the sawhorse one-handed using the inbuilt grip handles. I chose to leave a gap and designed this handle to make carrying the sawhorses easier around the workshop. The tops are made from 35x90mm lumber, so I created handles that fit accordingly.