Things You'll Need:
- Safety glasses
- Table or circular saw
- 2 by 6 inch boards
- Drill
- Clamp
- Decking screws 2 1/2 inch
- 1 by 4 inch boards
- 3/4-inch thick 9 by 36 inch plywood
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Step 1
Gather all your materials. Be sure you have safety glasses and know how to use your power tools properly and safely. Set your saw blade to a 15-degree angle. Make beveled edges along both sides the length of a 2 by 6 inch board 36 inches long. If you're making two, repeat the process with a second board.
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Step 2
Use 2 by 6 inch boards to create the legs. You need four boards cut to 32inches long for each sawhorse. Bevel the top and bottom ends of the boards at a 15-degree angle to allow the legs to sit flush against the top piece of the sawhorse and the floor.
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Step 3
Drill pilot holes into the four legs 4 inches from the edges. Clamp the legs to the top piece and secure the legs to the top with 2 1/2-inch decking screws. You can use nails instead, but screws give more stability and strength.
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Step 4
Create cross braces, which can also serve as support for a tool shelf. Measure about 14 inches up from the floor on your sawhorse. Mark the length and angle in pencil on a 1 by 4 inch board. Use your pencil marks as a cutting guide. The board should be flush with the legs when finished. Use this first cut piece as a template for your other three cross braces once you're certain it's cut correctly. Cut the other pieces.
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Step 5
Screw the cross braces to the legs, two on the inside and two on the outside of the legs. (For two sawhorses, you need eight 1 by 4 inch pieces.) Be sure you use pilot holes before screwing in your cross braces, as the wood will splinter without them.
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Step 6
Cut a piece of plywood or other wood for a shelf. This piece will lie across the cross braces. Secure it with screws. You can add a lip to your shelf to help keep tools from falling off when you're working.
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Step 7
Add a plywood or other wood top to your sawhorse to make your sawhorse even more useful. The top surface can double as a workbench. Use a 3/4-inch thick piece 9 inches wide and 36 inches elong. Again fasten it with screws, but this time in addition to drilling pilot holes, use a countersink or larger drill bit to create a countersink hole. Then insert screws. This will keep the screw heads from interfering with your workspace.
