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Step 1
Determine the length and height you want your sawhorse to be. Sawhorses can be built out of 2-by-4-inch boards or 2-by-6-inch boards. Anything wider will make them too heavy. For this application, use 2-by-4-inch boards.
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Step 2
Cut your first 2-by-4 to 48 inches. This is your top when you build a lightweight sawhorse. Cut four 2-by-4-inch boards 36 inches long. This will be used for the four legs of your sawhorse.
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Step 3
Lay your top piece on the floor with the 4-inch side showing. Now install two legs on top of the 2-by-4 at a 15-degree angle. Use a 16-penny nail and nail the two legs 2 inches down from the top. Turn it over and repeat the process, nailing the other two legs.
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Step 4
Stand the sawhorse up by spreading the legs at the bottom to at least 24-inches wide. Now cut a brace to hold the legs apart by using a 2-by-4 inch board. Nail them together with 16-penny nails. Repeat the process on the other end. Nail off the legs by using two more 16-penny nails at the top.
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Step 5
Lay a 2-by-4 flat up against each leg while the sawhorse is upside down and mark a line on the legs across the top of your spare board (the line will be closer to the bottom of the legs), so that you have a straight line guide. Now use a saw and cut your line at the bottom of each leg. This will allow all four legs to set level on the floor when you build a lightweight sawhorse.
