Sawhorses: Free Plans & Pix

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PROJECT 1:  SAWHORSE PLANS

Build a sawhorse for under $8 in less than an hour. This sawhorse project is suitable for anyone that can use a measuring tape, drill and circular saw. 

Following are Quick, Easy & Free Sawhorse Plans.

Click on pictures for enlargements.  Have fun.

Should I use screws or nails.  Click here for info.

Materials needed:  

Three - 8 foot' 2x4"s, 

Two - 4" wide 40" long pieces.  This piece can be anywhere from 1/2" up to 2" thick This is for the left to right brace pictured above and in Step 4. 

Approximately 50 - 2.5" wood screws.

Tools need:  Circular Saw, pencil, measuring tape, drill, drill bits & Bit-Grip.

Step 1:  Cut the pieces.   The first step is to cut most of the pieces you'll need.  Having everything cut in advance will speed you through the project.  

First cut 2 40" pieces.  These will form the ridge in step 2. Next cut the four 36" pieces. The four 36" pieces are the legs of your sawhorse.   All six pieces are cut from the 2x4's.  

Step 2:  Form the Ridge

The ridge is formed from the two 40" pieces cut in Step 1.

Put the 2 40" pieces together in a perpendicular fashion pictured to the left.  

Screw the two pieces together with at least 4 screws from bottom piece into top piece.  You may need to pilot holes for the screws.

Voila - we have the ridge piece!

Don't worry if observers aren't that excited by the step-by-step process.  They'll be impressed by the final product.

Step 3:  Attach the legs.  

Now we will mark the ridge for placement of the legs.  Measure 1 1/4" from top and 1 1/2" from right.  Make a mark. This mark is where you will position top outside corner of leg.  You will need to make this mark on both ends of both sides of the ridge.

Next we will attach the legs.   You can set the top pieces on the ground and then position first leg at mark you just made.  Be sure that leg is aligned at a 90 degree angle to top piece.  How do you know it is straight?  Use the reveal (the 1 1/2" of top piece showing) to line up the leg.   For a more exact line up use a carpenters square.

The picture to the left shows how it looks when the leg is accurately lined up.  The picture to the right shows an improper alignment. 

Screw leg to ridge with at least 4 (four) 2 1/2" screws.  Two of the screws should go into each of the top pieces.

Align each leg in same manner.  You're almost done.

Step 4:  Brace your new sawhorse.

Using leftover pieces, make a brace for between the legs.    Make a mark 12" from top of each leg.  This mark is for lining up brace so that you can mark it for cutting.  To mark for cut, hold brace against leg so that top of brace is flush with both marks.  Next hold pencil against leg while making a mark on brace piece.    Make this mark for both legs (If this is confusing click on picture for more detail - I hope this helps).  You will need a brace for both ends.  Cut 2x4 along these two diagonal lines.  This cut is best performed with a chop saw but can be done with a circular saw.  Be careful.

Place newly cut brace in place.  Screw in with at least two screws on each side.  Go from outside of leg into brace.  Repeat this procedure for both ends.

Brace legs side to side.    Attach a board (at least 4" wide) from left to right leg.  This piece should be screwed with at least 2 screws in each leg.  This is a brace used to stop side to side movement.  Braces are needed on both sides of sawhorse.  

Notice how once doubting onlookers want to take credit for your work.

Was this plan clear?  Was it helpful?  Email me with questions, comments or pictures of your sawhorses:  daniel@stuffwedo.com

Feel free to print the directions or e-mail them to a friend.   They are copyright protected so they cannot be sold or redistributed for profit.