DIY: How to Build a Height-Adjustable Sawhorse

Sawhorses are often used by woodworkers during project completion.

A sawhorse is a beam or flat surface that's supported by a leg assembly. Sawhorses are usually used in groups of two or more to lift or suspend objects of the ground to be altered, displayed or stored. Most sawhorses feature a static construction design, so they aren't collapsible or adjustable in any way. Dynamic construction designs for sawhorses are available and can be made out of the same basic materials.

Things You'll Need

• Measuring tape
• Pencil
• Circular saw
• 1-by-4 inch lumber
• 2-by-4 inch lumber
• 1-by-1 inch lumber
• 2/3-inch dowel
• 3 1/2-inch wood screws
• Drill
• 1/2-inch drill bit

Instructions

1. Measure, mark and cut four pieces of 1-by-4 inch lumber that are 24 inches wide. These will be the horizontal supports of your sawhorse.

2. Measure, mark and cut two pieces of 2-by-4 inch lumber that are 22 inches long. These will be the legs of your sawhorse. Measure, mark and cut two pieces of 2-by-4 inch lumber that are 12 inches long. These will be the bases of your sawhorse.

3. Measure, mark and cut two pieces of 1-by-1 inch lumber that are 20 inches long. These will be the risers of your sawhorse.

4. Measure, mark and cut two pieces of 1/2-inch dowel rod that are 6 inches long. These will be your adjustment pins.

5. Measure, mark and cut four pieces of 2-by-4 inch lumber that are 3 inches long. These will be the end spacers.

6. Measure, mark and cut two pieces of 2-by-4 inch lumber that are 15 inches long. These will be the middle spacers.

7. Lay one horizontal support in front of you. Position end spacers at each end of the support. Align the edges. Lay a riser next to each internal edge of the end spacers 1/4 inch from the spacer. The top of the risers should align with the top of the horizontal support. Center a middle spacer between the risers. Lay a second horizontal support on top of the risers and spacers. Secure the horizontal supports to the spacers and risers with screws.

8. Lay another horizontal support in front of you. Position end spacers at each end of the support. Align the edges. Center a middle spacer between the end spacers. Secure the horizontal supports to the spacers with screws.

9. Mark the spacers every 1 1/2 inches along the length of the riser, starting 1/2 inch from the bottom of the horizontal support assembly made in Step 8. Drill each marked area with a 1/2-inch drill bit.

10. Slide the bottom of the risers in the two spaces in the second horizontal support assembly. Insert one adjustment pin into each riser at the same horizontal level to position the top of the sawhorse.

11. Position the legs of the sawhorse on each end of the bottom horizontal support assembly. Align the top and sides of the assembly with the top and sides of the legs and secure the pieces together with wood screws.

12. Lay the two bases on a flat surface with the widest edge face down. The longest sides should be vertically positioned. Position the top of the sawhorse vertically and center the legs on top of the bases. Secure the legs to the bases with wood screws.

Tips & Warnings

• The height of the sawhorse can be adjusted by removing the dowel rods and moving the top horizontal assembly up or down. Secure the dowel rods in the holes directly above the bottom horizontal assembly to secure the sawhorse in place.

References

• "The Family Handyman": Workshop Organization Tips; February 2003
• Pregnant...with Power Tools: Adjustable Height Storage Sawhorse