Build Sawhorses: Even Better Than In 1985

| 5/22/2009 4:50:11 PM

Tags: DIY, safety,

sawhorse complete

I decided to build some cheap shelves for the basement and was cutting some 2-by-4s on the floor when the saw kicked back. I wasn’t injured, but it was a stupid thing to do. Using sawhorses to keep the wood in position is much safer, so I decided to build a pair.

I used the $6 sawhorses (Build the World's Best $6 Sawhorse?) as a model, but changed a few things to fit my needs. (The sawhorse plans are in the Image Gallery for that article.) You can build these with hand or power tools. I used a combination. Here’s how I built the sawhorses step by step:

Make the Top

Cut the following pieces of 2-by-4 to length.
4 pieces, 10 3/8 inches long (this is slightly more than the original plan)
2 pieces, 14 inches long
2 pieces, 19 inches long
2 pieces, 36 1/5 inches long (this is slightly more than the original plan)

Lay out the longest pieces with a 10 3/8-inch piece on top of the ends to make a rectangle. Square up the corners and attach with four 2 1/2-inch screws at each joint. I had to pre-drill the holes to avoid splitting the pine, even though I was using self-tapping deck screws.

Put the other two 10 3/8-inch pieces in the middle of the rectangle. You’ll know where these fit if you put the 14- and 19-inch pieces on top of them for reference. The 14- and 19-inch pieces should reach the ends, leaving a 3 1/2-inch gap in the middle. This gap is wide enough to fit a 2-by-4, but should be narrow enough that the foot of your circular saw will bridge the gap. (In the original plans, this gap was only 3 inches, but I thought I might want to put a 2-by-4 between the two sawhorses sometime, so I made it a little wider.) Attach the middle 10 3/8-inch pieces with four 2 1/2-inch screws at each joint.
5/5/2018 3:04:28 AM

I used the plans at WWW.EASYWOODWORK.ORG to build my own sawhorses – I highly recommend you visit that website and check their plans out too. They are detailed and super easy to read and understand unlike several others I found online. The amount of plans there is mind-boggling… there’s like 16,000 plans or something like that for tons of different projects. Definitely enough to keep me busy with projects for many more years to come haha Go to WWW.EASYWOODWORK.ORG if you want some additional plans :)

11/21/2011 12:16:30 PM

These look excellent, though the drawback could be one of space if you have a small workshop. I like the top which provides space for cutting and holding timbers, such an arrangement could also be built into a workbench. Maybe if the top could be detachable from folding legs so as to 'flat-pack' for storage.

Dan Baumgardner
6/9/2009 1:35:14 PM

I have built, used and given away many of "the best $6.00 sawhorses". It is by far the most stable platform for woodworking as well as scaffolding. However they don't cost just 6 bucks anymore but they are still worth the $ and time to build. If fact I still have the original Mother Earth mag. featuring the horse and the next issue that had the measurements that were accidently left out of the first set of plans.

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