How to Build a Quick and Easy Sawhorse

by Brett on September 15, 2011 40 comments in Manly Skills

A few months ago, raftsman flew me !p to hicago to "isit their raftsman #$perience shop for a blogger s!mmit% &'f yo!(re e"er in hicago, ' )efinitely recommen) stopping by the raftsman #$perience an) checking it o!t% 't(s free an) open to the p!blic%* ' spent the )ay playing with tools an) learning how to b!il) "ario!s pro+ects !n)er the t!telage of se"eral ,'- bloggers% .ne pro+ect that ' really en+oye) an) fo!n) pretty )ang !sef!l was from /imothy ,ahl, owner of the ,'- blog harles an) 0!)son% /imothy showe) !s how to make a simple, yet st!r)y sawhorse that e"en a han)yman noob like myself co!l) b!il) witho!t screwing !p too m!ch%

Why Do I Want to Build a Sawhorse?

1oo) 2!estion% Sawhorses come in han)y in a "ariety of sit!ations% /he first an) most ob"io!s sit!ation where a sawhorse is !sef!l is when yo! nee) to saw something% ,!h% A sawhorse gi"es the boar) yo!(re sawing the s!pport an) ele"ation yo! nee) to make a clean c!t% A pair of sawhorses can also be !se) to make a makeshift work table or scaffol)% 3!st !se the two sawhorses as the legs, an) place a sheet of plywoo) o"er it% 4hen ' worke) as a painter one s!mmer back in high school, my boss wo!l) !se a pair of sawhorses an) an ol) )oor he fo!n) on the si)e of the roa) to make his worktable% Makeshift tables from sawhorses partic!larly come in han)y when yo!(re setting !p for a garage sale%

5et(s see% .ther reasons yo! sho!l) b!il) a sawhorse6 0ow abo!t for a makeshift seesaw7 .r what abo!t !sing it as the f!lcr!m for a home )efense catap!lt7 3!st spitballin( here% An) while yo! can certainly b!y rea)y8ma)e sawhorses at yo!r local big bo$ har)ware store, yo! miss o!t on the f!n an) satisfaction of b!il)ing a piece of e2!ipment that will ser"e yo! for years to come%

Materials
0ere are the materials /im recommen)s for his sawhorses% 't(s eno!gh to make a pair%

Si$ 92:8inch 2$4s &for the '8beams* #ight 908inch 2$4s &for the legs* /wel"e 98inch woo) screws /hirty8two 1;, gal"ani<e) nails

How to Build a Sawhorse

B!il)ing a sawhorse is s!per easy% 't makes for a great starter pro+ect for the man who has ne"er really worke) with tools, b!t wants to become han)ier aro!n) the home% =ote> /his is one way to b!il) a sawhorse% ' know there are plenty of other ways to )o it% /his plan is great for e"ery)ay !se in a typical s!b!rban garage% 'f yo! plan on !sing yo!r sawhorses for hea"y work, yo! might try another )esign% 1. Measure and Cut Your i!"er

/he 2$4s ' bo!ght came in lengths of si$teen feet, so ' ha) to c!t them )own to the nee)e) si<es% 0ere ' am meas!ring an) c!tting 92:8inch pieces for the '8beams an) 908inch pieces for the legs% ?emember to meas!re twice an) c!t once@

0ere ' am !sing a portable compo!n) miter saw to c!t the timber% -o! can !se a han)8hel) circ!lar saw or e"en an ol)8school han)saw%

?ea)y to be t!rne) into a sawhorse

#. Build I$Bea!s

/ake three of yo!r 92:8inch 2$4s an) screw them together in an A'A formation%

' fo!n) it helpf!l to )rill a pilot hole before )ri"ing the screws in%

,ri"e three woo) screws right )own the mi))le on top an) bottom of the '8beam% Blace two of the screws near each en) an) )ri"e the other one right in the mi))le of the '8beam%

Cinishe) '8Beam %. &ail the 'e(s to I$Bea!

B!tt the en) of the 90A 2$4s into the top of the '8beam like so% 0ammer two nails at the top of the leg so that they go into the mi))le '8beam piece%

=ail two more nails into yo!r leg so that they go thro!gh the bottom '8beam piece%

'f yo!D"e )one things correctly, yo! sho!l) form a bo$ pattern with yo!r nails% =otice my hammer )ings in the woo)% ' nee) to practice%

?epeat for each leg%

Co!)leted Sawhorse

My finishe) sawhorse% ?inse, wash, an) repeat to make yo!r secon) sawhorse for a pair% /o store these ba) boys, +!st stack Dem% 0a"e f!n@

*elated +osts

1%

0ow to B!il) the Best Snowman in the =eighborhoo)

2%

Eitchen C!n)amentals> Basic Enife Skills

9%

0ow to B!il) St!r)y Basement Shel"es

2 ,o!g September 15, 2011 at 9>91 pm -ep, the classic saw horse, co!l)n(t get m!ch simpler% 9 /im September 15, 2011 at 9>40 pm Since yo! !se) screws to hol) together the i8beam why not +!st !se screws to attach the legs as well7 /hey wo!l) certainly hol) better% 4 hris September 15, 2011 at 4>02 pm 4hat /im sai)% =ails ten) to pop o!t o"er time whereas woo) screws stay p!t% 5 ,!sty September 15, 2011 at 4>54 pm 6or !se a combination of screws an) nails% Best of both worl)s% ; /imothy September 15, 2011 at 5>2F pm 4ell )one Brett@ /he abo"e comments are right% -o! co!l) certainly !se screws for the entire +ob an) it wo!l) )efinitely be more sec!re b!t this e$ample )emonstrates that how G2!ick an) easyH this sawhorse is to b!il) with whate"er materials yo! ha"e a"ailable, especially on a +obsite% #"ery +obsite typically has a framing nailer which also makes the set!p e"en faster I Mike .DBrien September 15, 2011 at 5>9F pm 1reat work, as !s!al% keep it !p@ 10 em)ash September 15, 2011 at ;>5I pm '() b!ry the screws on the top of the sawhorse halfway thro!gh the top most 2J4% Kse a forstner bit or +!st a )rill bit with a larger )iameter than the hea) of the screw to create a 9L4M )eep Npocket( before )rilling an) )ri"ing% 0itting a screw hea) with a circ!lar saw is no f!n@ Also, ' think the i)ea of !sing nails rather than screws on the legs is so that they )o work loose a bit% A little bit of fle$ in the legs makes it easier to set !p on !ne"en gro!n)% An) yo! can always po!n) the nails back in when yo! nee) to% 11 Ben1 September 15, 2011 at F>29 pm

/his is act!ally one of the strongest ways to p!t together a sawhorseOfastening to the bottom of the '8beam ens!res the strength% -o! can set an entire b!nk of plywoo) on a pair of those@ /hey(ll o!tlast the Ghea"y )!tyH plastic ones by a mile% '("e ha) one pair in constant !se for si$ years r!nning, the only thing ' )o )ifferently is a)) a co!ple of cross pieces towar) the bottom of each pair of legs, an) then a 2J4 across those &parallel to the ' beam*% /hen yo! can store material !n)er the saw horses tooOoff the gro!n)% .h, an) it(s easier on yo!r back to make the legs 9;M tall !nless yo! are e$cl!si"ely !sing a han)saws% 14 Mike September 15, 2011 at 11>22 pm /his is the best )esign for )ea) simple, cheap saw horses that '("e seen an) they are probably great if yo! ha"e the floorspace, b!t '(ll stick with my tr!sty fol)ing steel ones with the 2J4 screwe) to the top% /hey hang on pegs when not in !se 15 Ben1 September 1;, 2011 at 12>00 am .ne )etraction to bracing the legs, tho!gh, is that yo! can(t stack them% 1; 1F1;home%net September 1;, 2011 at 12>2I am 4o!l) it not be the easiest thing in the worl) if yo! c!t 14 pieces that were all 99 inches long7 1I September 1;, 2011 at 2>0I am ' agree with the abo"e poster% 's there a benefit to ha"ing the legs a bit shorter than the i8 beams are long7 1P An)rew September 1;, 2011 at 2>10 am QBen1 =ot necessarily% -o! co!l) p!t a bo$ aro!n) the bottom on the o!tsi)e of the legs% 'f yo! go low eno!gh, yo! co!l) still stack them% At least, it works in my hea)% 1F 3ohn B September 1;, 2011 at 9>04 am 'f yo! p!t a compo!n) angle on the legs, it will make a m!ch stronger sawhorse% =ot 2!ite as simple, b!t worth it% ' ha"e a pair of tro+ans http>LLwww%tro+antools%comLcatalog%htm they(re nice, b!t spen)y

25 5en 5% September 1;, 2011 at 1>44 pm 5o"e it6"ery simple )esign that )oesn(t in"ol"e any miter or be"ele) c!ts6 /he '8 Beam is great beca!se now yo! ha"e an e$cellent s!rface to clamp to when working with other pieces of woo)% =ow ' +!st want a simple Nsawb!ck( how8to >* 2; Ee"in September 1;, 2011 at I>40 pm 'f yo! mo"e the legs all the way o!t to the e)ge, yo! can a)) bracing on the o!tsi)e an) still allow for stacking% 2I /hese!s September 1;, 2011 at F>2P pm As #m)ash sai) abo"e, the !se of nails on the legs is to gi"e some wiggle to the legs to make set!p on !ne"en s!rfaces easier% 2P /hese!s September 1;, 2011 at F>90 pm As sai) abo"e, the !se of nails on the legs is to gi"e some wiggle to the legs to make set!p on !ne"en s!rfaces easier% 2F Br!ce 4illiamson September 1;, 2011 at 11>2F pm Kh ' +!st !se the plastic man!fact!re) kin) from Stanley% /he height is a)+!stable so ' can make them the same height as my table saw an) !se them for in fee) an) o!t fee) s!pport% ' ha"e fo!r of them for s!pporting 4JP sheets when ' nee) to c!t them% 90 /he Bobster September 1I, 2011 at 2>01 pm ' +!st !se a set of metal clamps )esigne) to make a sawhorse% 3!st slip in the 2J4Rs% Car easier to assemble an) store% =ot as manly tho!gh% 91 3!stin September 1I, 2011 at 10>04 pm /his remin)s me of my )a) an) when ' was yo!nger% 0e was a carpenter an) always ha) se"eral sets at the ho!se he was working on or a co!ple in his tr!ck% /his are fancier than the ones he e"er ma)e as he ha) the Gi8beamH be one 2J4 that was "ertical an) the legs wo!l) be naile) or screwe) )irectly to the si)e, b!t wo!l) ha"e miter c!ts on the en)s to make the line !p an) angle o!t correctly% 0e wo!l) then take the 2J4 scraps he ha) an) nail them on the legs as cross beams, maybe c!tting them )own a bit for a better fit% 't wasn(t pretty, b!t he really )i)n(t want pretty% 0e co!l) keep his skill saw at a )eep le"el an) if it c!t thro!gh it wo!l) +!st hit the 2J4 !n)erneath a bit% /he wo!l) !s!ally go in

the scrap after the ho!se was complete)% /hanks for the memory@ 92 5a!ra September 1I, 2011 at 11>4I pm 4e(re planning to rep!rpose an ol) beat8!p pair of sawhorses to s!pport a )o!ble &meat* rabbit cage so bring it !p to a better height% 4e(ll attach it to the the sawhorses to pre"ent it from being knocke) off an) probably tether the cage to the wall of o!r henho!se to keep it from tipping o"er% 4e keep worm compost bins beneath the cages to catch the )roppings an) !se the res!ltingHblack gol)H in "eggie be)s% 99 g kaiser September 1P, 2011 at 1>40 am ' think that a saw horse sho!l) be collapsible for easy storage% 't also makes sense if there is some kin) of hol) of the item to be worke)% ' wo!l) th!s s!ggest that yo! cross the legs close to the top, an) bolt them together, so they can fol) o!t, when !se), creating a S on top, in which the item rests, sec!re) while being worke)% 4hen storing, +!st fol) together an) p!t away flat% #asier in e"ery way% 94 ,on September 1P, 2011 at P>40 am em)ash is right abo!t the screws in the top% .ne of the main !ses for a GsawhorseH is s!pporting woo) that yo! are c!tting with a saw% -o! will be r!nning the saw bla)e thro!gh the top of the horse% An) the screws, sooner or later% 95 Cre) smith September 1F, 2011 at I>9F pm Are yo! serio!s7 Cirst of all with the ' beam they are too hea"y% Secon)ly witho!t any leg bracing they are going to fall apart with weight on them% /hirg the legs sho!l) be bea)e) so they sprea) apart% Blywoo) g!ssets wo!l) make things a lot more stable% 9I ka!fman September 22, 2011 at 12>2I am 1reat an) simple collapsible horses@@@ Simply lie two 2J4Rs on the gro!n) parallel to eachother a bit longer than )esire) height of horses&these will be yo!r "erticals*% Screw a 2J4 perpe)ic!lar to the other two, at their en)s% 't(s length is )etermine) by the )esire) wi)th of yo!r horses&hori<ontal brace*% Screw another 2J4 appro$% half way )own an) perpen)ic!lar to yo!r initial two parallel "ertical s!pports% ?epeat this process three times for a total of fo!r matching% =e$t lay two of these en) to en), hori<ontals facing !p% /he top hori<ontal braces sho!l) now be parallel an) ne$t to eachother% Attach with two ol) )oor hinges with the cylin)er of the hinges facing )own% Col), the wings of the hinges sho!l) point )own% ,rill a hole thro!gh the center of each lower hori<ontal 2J4 brace% Cee) a rope thro!gh both holes an) knot one en)% .pen horse !ntil yo! are satisfie) it will be stable knot the other en)%

?epeat for yo!r horse(s mate% =ow yo! ha"e collapsible horses@@ Always remember to set yo!r saw bla)e to the correct )epth@@ /his is important for c!tting anything on any s!rface, be aware of what yo!(re )oing an) where yo! are c!tting@@ woo)c!tting bla)es an) metal )o not mi$% -ester)ay ' co!l)n(t spell carpentar to)ay ' is one@@ 9P Mark Betersen September 22, 2011 at 5>2I pm 'f yo! wante) to brace them in a way that wo!l) allow yo! to still stack them, !se 1J2Rs an) angle the en)s to match the angle of the legs an) p!t them between the legs rather than the insi)e or o!tsi)e% 9F Brian September 29, 2011 at 1>5I pm =ice horse, hoss% 'f yo! prefer a fol)ing "ariety, '("e fo!n) a great g!i)e at the tear)rop trailer for!m ' fre2!ent> http>LLwww%mikenchell%comLfor!msL"iewtopic%php7tT95;FF%