How To Build A Lightweight Sawhorse How To Build A Lightweight Sawhorse

What You'll Need
Table or circular saw
Drill
Clamp
2 X 4 inch boards
1 X 4 inch boards
3/4 inch thick 9 X 36 inch plywood
2 1/2 inch Decking screws

A sawhorse is a great thing to have if you do a lot of carpentry or painting. They can also provide extra work space for those larger projects. While you can buy sawhorses and they aren’t unreasonably priced, it is still cheaper to build them yourself. Also, if you build it you can adjust the sawhorse plans and make it according to your needs and specifications.

Plan Ahead

In order to make your sawhorse lightweight, it is recommended that you use 2 X 4 boards. Anything larger will make moving your sawhorse cumbersome. Cut a 36 inch piece of 2 X 4. Then, setting your saw blade to a 15 degree angle, make beveled edges on both sides of the cut piece. This will be the top of your sawhorse.

Prep Work

Cut 4, 32 inch 2 X 4 boards that will form the legs of the sawhorse. The top and bottom of each piece will need to be beveled at a 15 degree angle so that they will sit flush against both the top piece and the floor.

Drill pilot holes into all four legs 4 inches from the edges. Clamping the legs to the top piece of the sawhorse, secure them using 2 ½ inch decking screws.

Make Cross Braces

Starting at the floor, measure up 14 inches on your sawhorse and mark the spot on both legs of one side of the sawhorse. Then, measure the distance between the two marks. This is how long you will need to cut the four 1 X 4 boards that will make up your cross brace. Because the legs are on an angle, you may have to put an angle cut in the brace boards, so that they are flush with the legs. Repeat for other side of sawhorse.

Drill pilot holes into the cross braces where they will be screwed in. Screw two on the inside and two on the outside of each legs.

Add a Shelf

Once you have your cross braces installed, you can use them to anchor a shelf so that you have a place to set your tools while working. Measure from one side of the sawhorse to the other where the braces are. Cut a 2 X 4 board according to your measurements. Attach with screws.

Finish the Sawhorse

To add a bit of strength and versatility to your sawhorse, add a piece of wood or plywood to the top. If you want a wider surface, you can always add a piece that is wider that the sawhorse.

When adding the top piece, make sure to drill pilot holes before screwing it in. Also, use a countersink or larger drill bit so that you have a countersink hole. This way, once the screws are in, they will be below the wood surface and won’t interfere with the top of the sawhorse. 

Got a New Project You're Proud of?

Post it on Your Projects!