Sawhorse plans family handyman, Framing carpenters usually build these horses when they show up at a job site. It’s not unusual for the home owner to end up with a pair of saw horses and have them around for years. My top choice of wood for this project is redwood, which is readily available here in California. The concept grew from my frustration at being unable to find a lightweight, compact, folding saw horse that I could take to and from job sites. I’ll be back later on this week to share why I made these kid-height DIY sawhorses.
These aren’t screwed in because they are meant to be replaced as you cut them with your saw while making cuts. As a carpenter, I also wanted it to be as stable as a non folding sawhorse, very strong and durable, and, if possible, look professional. If I need another one, I can use the existing ones along with a pattern-copying router bit to make a third in no time. The next reason why building these sawhorses is important to share is because small projects are critical to learning to work with one another. Here’s how the side supports also work like shelves to hold wood in a vertical orientation.
Six eight-foot, 2×4 wood studs will provide enough material to build a four-foot-long sawhorse. Please use the best workholding solution you have; I just have a desire to make simple projects with basic stuff. Mark a line 8 in. up from the bottom of the leg, line up the bottom of the 2×4 with that line, and attach it with two 3-in. I predrilled two holes on either side and then used the band saw to cut an open latch in one side.
Try to get them down about 1/4 inch below the surface of the wood and then make sure you don’t cut that deep when you cut across your sawhorses. It’s this easy to carry 2 folding sawhorses in 1 hand with their comfortable handle and compact shape! Blocks of wood to temporarily hold the shelf in place while you fasten the hinged side of the shelf to the legs. Another version of the folding saw horse I’ve seen has a hinged shelf in place of the chains.
These sawhorses follow this technique and will look as good in your workshop as they would in your home. If you find that they are starting to get a little wobbly, add a couple screws or nails to each leg and you can make them sturdy again. Then make several spaced crosscuts across the width of the joint, and use a chisel to clean up the waste in the notch. By putting the saw horses up against the squat/bench stands as shown below, you effectively turn your squat stands into a power rack. The skill level for building these job site sawhorses is rated for a novice, or DIY person.
Actually, it is the only foldable saw horse priced below $150 that combines even seven of the important features listed at the top of this page. In addition, we make every effort to obtain the raw materials as close to our production sites as possible in order to reduce fuel consumption in transportation. When measuring, keep in mind that if you make angled cuts (see below) to the bottoms of your sawhorses, you’ll lose a little height, and you’ll probably be standing on a mat for comfort, which will add a little to your height. Some sawhorses have a shelf and some fold up, but Jeb’s design combines both features. A pair of sawhorses can also be used to make a makeshift work table or scaffold.
The popular choices seemed to be either sawhorse brackets or plastic sawhorses But after a little research and some sketching, I decided that I could build a homemade pair for less with just five 2x4s and a few strap hinges. Cut them using a Dremel Ultra-Saw, which can make simple straight cuts like these but is also perfect for wood flush cuts, grinding and cutting metal by switching out the included attachments. And yes, we had to build them under the house like a community of mole people because it’s New Orleans and it rains a lot.
And while you can certainly buy ready-made sawhorses at your local big box hardware store, you miss out on the fun and satisfaction of building a piece of equipment that will serve you for years to come. After I drove the first screw in I used my framing square to make sure the leg was square to the top before I drove in the next screw. Our sawhorses are far from perfect, but they are perfect for what we will be using them for!
For ease of set up, transport and storage I’ve always gravitated toward the folding plastic saw horse. The Shop Boss from A.W. Engineering joins two metal legs with a 2×4 backbone to create a folding horse/bench hybrid. A sawhorse gives the board you’re sawing the support and elevation you need to make a clean cut. I spent the time to build this knowing that this project was going to take be awhile.
Building these sawhorses is an opportunity to teach children how to use a few different power tools and it’s up to you to decide how comfortable you are with teaching them. It is suggested you build your horses a bit tall, since the legs can be trimmed when they are complete to fit the user. When I relax and exhale, the saw horses are then tall enough to take the bar off my hands so I can breathe and roll it down to get out from under it. I suck at Bench Press so I can’t imagine lifting alone without these. The first and most obvious situation where a sawhorse is useful is when you need to saw something.
During the creation of the I-beams — used to improve stability and rigidity of the sawhorses in this case — George divulges a handy tip to easily keep track of the center line of long boards when making connections from the outside edge. Some sawhorses are built on the job site using scrap materials and some use complex wood joinery and show the pride and skill of a master craftsman. I cut mine to 21″ long because I wanted my sawhorses to be kid-height (for a fun project I’ll share later on this week) but you can make yours however tall or short you’d like. The standard measurements are given first followed by the metric measurements in brackets ( ). For example: 2×4 (100mm x 50mm).
With an inexpensive ($ ish) piece of dimensional lumber at top, you can have no qualms about drilling or cutting into the top of your saw horses, lessening tearout, and making for safer and stronger operation. There are several options to look at if you’re interested in buying folding sawhorses. When you build your perfect pair of sawhorses you can sit back and look at them and think, You are a Jedi now!” Yeah, something like that.
I don’t want pretty sawhorses that I’d be afraid to mess up. I want to be able to spill paint on them, accidentally cut them with my skill saw, and maybe back into them with my car. The real (actual) sizes of the wood will be a little less once the wood has been dimensioned (dressed, planed). A quick aside: This project has reminded me of the value off a good crosscut backsaw, something I grew up knowing only as a tenon saw.” I sense that many have found value with rip profile teeth for this type of work, but I would not want to be without the precision of a crosscut saw in my arsenal.
Building a sawhorse is super easy and there are several ways to build sturdier, stack-able and more permanent versions. And of course I wanted to make the new sawhorses out of stuff I had lying around my garage. The lumber we used for these sawhorses weren’t good enough to build much with, but the pieces were perfect for our needs. I got to thinking about what characteristics I’d like replacement sawhorses to have. Most often, 8d and 16d nails are used in saw horse construction, but lag screws can also be used.