How to Build a Strong Sawhorse

No woodworking project or home renovation would be complete without a strong set of sawhorses to support your work. A sawhorse allows you to elevate your work off of the ground, giving you easier access and a more comfortable working position for sawing, cutting, routing or drilling. Sawhorses are usually used in pairs and can be purchased ready to use. You can save a lot of money by making your own set of sturdy sawhorses from pieces of lumber you may already have and a few carpentry tools.

Things You'll Need

• 32 1/2-inch 2x4 lumber, 3
• 30-inch 2x4 lumber, 4
• 12x12-inch quarter-inch plywood, 2
• 32 1/2-inch 1x6 lumber, 2
• Circular saw
• Hammer
• 16d common nails, 16
• 8d common nails, 20

Instructions

1. Cut the lumber specified in the material list to the required dimensions using a circular saw. Have all pieces cut before beginning assembly of the sawhorse.

2. Create an "I" beam with three pieces of 2x4 30 inches long. Do this by lying one piece flat on the ground. Stand the next piece lengthwise on its edge and centered on the piece lying flat. Center the third piece flat on top and secure with four 16d nails evenly spaced. Turn the assembly over and secure the other side with four 16d nails. (A cross-section of the finished assembly should look like an "I.")

3. Use four 30-inch pieces of 2x4 lumber as the legs for your sawhorse. Secure one leg on each corner of the "I" beam with two 16d nails. Nail the top of each leg into the center section of the "I" beam. Drive another nail through the leg and into the lower horizontal part of the beam. (This enables the legs to have to correct angle.)

4. Secure a piece of 12x12 quarter-inch plywood with eight 8d nails in the end of the sawhorse legs. Repeat this procedure for the other side of the sawhorse. (This keeps the legs from spreading apart when weight is put on the sawhorse.) Use the legs as a guide and trim the excess plywood with a circular saw.

5. Use two pieces of 32 1/2-inch 1x6 lumber as braces and nail to the outside of the legs on each side of the sawhorse with 8d nails. Make sure the brace is approximately 12 to 14 inches off the ground.

Tips & Warnings

• The material list and procedure allows for making one saw horse. For a pair of sawhorses, double to amount of lumber pieces and nails and follow the same procedure.

• To make sure the legs are even on your sawhorse, nail the legs onto the beam with the assembly sitting on a level floor.

References

• Shopping Matchmaker: The 14-Minute Sawhorse