The sawhorse is a familiar sight in on construction sites, or in the bed of a contractor’s pickup. It’s not unusual for the home owner to end up with a pair of saw horses and have them around for years. Now you can cut a couple notches in the top boards to accept 2x material on edge to span both horses. Six eight-foot, 2×4 wood studs will provide enough material to build a four-foot-long sawhorse. Install 2x6s on the top as sacrificial surfaces that can be cut into without damaging the horse or a saw blade.
Kinda overkill, but If i had the time, space for storage and budget, I’ll construct the same saw horse just like sportbugger’s. The horses in the illustrations required 2- 10 foot 2X6 boards, which were ripped to 2 3/4 inches wide, yielding 40 feet (12.2 m) of lumber. This post is about wood sawhorses specifically and why they are still a good all-around fit for today’s jobsites. If you plan on using your sawhorses for heavy work, you might try another design.
These are not simply sawhorses (strong ones, at that!), but they represent a much larger part of our journey which is practice. As shown in the picture below, you can save a bit of time by setting your saw at 19 degrees when cutting the boards in described in step one. The 3/8-in.-deep mortises in the 2×6 top are made with a circular saw and a sharp chisel.
A sawhorse can also be used as the base for a portable work table by placing a sheet of 19 mm (3⁄4 inch) plywood or even a door on top of two sawhorses. When we saw we do not compress the knife wall because we don’t mallet the chisel, which does compress andover knife wall. For ease of set up, transport and storage I’ve always gravitated toward the folding plastic saw horse.
I believe we can complete the second one in well under an hour – just ran out of time after figuring out the first with minimal instructions. The plan is very sturdy and easy to do. however i have one quick question, I am having trouble in aligning the I Frame to the center piece. STORAGE IS SIMPLE: Compact box-like folded form makes these folding sawhorses easy to stack, stand on end, or hang on a wall. It became clear that in order to get what I wanted I would have to learn how to build sawhorses. Sawhorses are essentially comprised of three components: the top (or box), the legs, and the leg brace.
We use our foldable saw horses to make portable tables and work benches in the production shop because they are as stable as non folding sawhorses and allow the flexibility to easily disassemble the work benches when not needed. 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.
Working on a pair of sawhorses instead of a workbench is a simple but very efficient way of establishing a comfortable place to do any kind of woodwork you can imagine. Screw it on in the flat position, making a T. That way you can let your saw cut into it, it’s sacrificial and easily replaced, also it will give you a wider surface to work on, handy for when your ripping boards, just run a pair of screws in, mark your line and cut with your circular saw.
Only one suggestion i would add is: add a 3/8″ drill thru hole, or whatever is closest to the radius of the 2×4 corners, before you jig saw the 90 degree notches. This video on how to make sawhorses provides you with all the steps necessary to get a beautiful finished product. I got to thinking about what characteristics I’d like replacement sawhorses to have.
You could also build various height cross members to support differing infeed / outfeed support heights. The first and most obvious situation where a sawhorse is useful is when you need to saw something. I have thought about building one myself for many years but the truth is that I never really needed one, I could always get all the work done just as easy without the need for such a fancy device. The first and most obvious situation where a sawhorse is useful is when you need to saw something. Our sawhorses are far from perfect, but they are perfect for what we will be using them for!
It is suggested you build your horses a bit tall, since the legs can be trimmed when they are complete to fit the user. A popular option Available at home centers everywhere, these sawhorses ($60 per pair) have selfleveling, adjustable legs that keep the horse steady on uneven terrain, but it’s easy to lose the leg extensions and the bolts that secure them. Note that you can cut all four legs at one time if you have a compound saw that will cut a 4×8 inch stack of 2×4’s. Using a table saw or miter saw, cut the ends of each 31.5 inch board at a 19 degree angle.
Light duty is fine; I’m typically going to be using them to hold boards to cut with a circular saw in the back yard. You could build them with only a circular saw, but using a tablesaw for beveling the top and a sliding miter saw for cutting the legs makes the process much easier. The ideas are right at your doorstep but bringing some modifications to them will enable you to build some timeless masterpieces with minimum expenditure.
The combination of strength and stability in such a light weight, compact foldable sawhorse still amazes me. I’ll say it again, I’ve tried nearly every foldable saw horse available, and the HideAHorse is the best by far – no doubt. Since they’re held together with screws in soft wood, the screw holes gradually expand and make the sawhorses prone to wobble and fall apart.
Stand your partially assembled horses upright, and measure down from the bottom of your top board about 8 inches (20cm), and using a short board, scribe it to be a horizontal spreader brace to fit between the legs. The plywood shelf makes for a handy place to set a circular saw or clamps while using the horse, but mostly it acts as a cross brace to provide stability.
I don’t worry much about leaving my workstation set up outdoor—I don’t care if the sawhorses get wet, muddy, cut into, or forgotten when the project is done, because I can always make a new set from scraps in the shop. I really think these sawhorses will help do that for me. I haven’t had a chance to use them yet, but I’m hoping that the first time I set a board on them to make a cut I’ll feel a sense of satisfaction at using a well-built tool that’s perfectly suited to the job at hand. This simple folding sawhorse design from Steve is very easy, quick, and will solve the storage problem basic sawhorses cause.
I could have drawn a CAD drawing but what I had in mind is so straight forward that I could just lay it out and build it. No need to waste any time on drawing when everything is crystal clear in your mind. Set up a work table or other surface to measure and cut the lumber on. Since you are building the saw horses, it can be assumed you don’t already have a set available, but if you do, of course use them. I predrilled two holes on either side and then used the band saw to cut an open latch in one side.
Job site sawhorses like the ones we build will take a PRO 15 minutes to build and a DIYer 30 minutes, assuming all of your tools are set up. My father made saw horses once about 20 years ago, without the help of the internet or plans of any sort. Back then we called saw horses mules,” and shorter versions were called ponies.” We often made and combined the small ones with planks for interior work such as installing crown molding. I’m tempted to make one of these horses to match my sawyers bench as a support for longer pieces.
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. But after a while, you’ll begin to realize that it works with shorter boards as well, and gives you the option of using a circular saw in the center or a handsaw at the ends. George will walk you through the step-by-step process for how to make sawhorses and shop stools using only two sheets of plywood. These sawhorses follow this technique and will look as good in your workshop as they would in your home.