Building Your Own Sawhorse

A home-made sawhorse is probably the least expensive accessory that you will need to acquire on the jobsite. A wooden sawhorse made from 2x4 lumber is easy to make and will last indefinitely. Measuring and cutting long lengths of lumber is much easier if the lumber is stacked across 2 sawhorses. Sawhorses can also be used to support scaffolding planks that will allow you access to almost any part of a 1-story building (so you may want to build at least 2).

Step 1 - Assemble the Crossbeam or "Back" of the Sawhorse

The sawhorse can be built to any length, but the height is fairly standard. (6) 8-foot 2x4 wood studs will provide enough material to build one sawhorse 4 feet in length. Assemble the sawhorse using #16 nails.

To begin, cut (3) 2x4 boards each to a length of 4 feet. Position one of the boards so that the edge (2 inch thickness) is centered parallel and perpendicular on the flat side (4 inch width) of the second board, forming an elongated “T”. Nailing through the outer width of the first board into the edge of the second board, join the boards together with 1 foot spacing between nails. Take the remaining 4 foot board and place its 4 inch width flat against (perpendicular to) and parallel to the opposite edge of the middle board. Attach with nails as described so that the entire assembly resembles a small wooden “I” beam.

Step 2 - Attach the Legs

Cut 4 legs from the 2x4 boards, also 4 feet in length. At both ends of the ”I” beam and on each side, angle the top end of each leg into the “U” shaped pocket flat against the side of the ”I” beam so that it butts up under the top "flange” (top horizontal component) and the “web” (vertical component). This will cause the legs to angle outward from the “I” beam at about 40 degrees from each other. Drive 5 nails through the top end of each leg into the “web” and the bottom “flange”. It will not be a  firm connection until the legs are fully braced.

Step 3 - Install Bracing

Cut 2x4 lengths that will brace the legs diagonally to the “I” beam. Nail one end flat to the outside surface of each leg at about 1/3 the height of the leg and the other end near the center of the “I” beam. Brace all 4 legs in this way. Cut lengths of 2x4 for the horizontal leg bracing. Install the braces flat against the legs at a height about midway between the ground and the top of the “I” beam. These boards will wrap around all four legs to form a rectangle, bracing each leg to the adjacent leg. They will also act as a step for climbing up and standing atop the “I” beam, so install them at a height that feels comfortable. Nail the braces securely to the legs.

Step 4 - Try it Out

Set the sawhorse on a level surface and check to see if it rocks. If necessary, trim the legs until it stands firmly on all four legs. If the sawhorse is to be left outdoors exposed to the elements, you can purchase pressure-treated lumber or you can apply a protective wood finish.