I have seen some pretty fancy saw horses here on the internet. Some fold up and hang on the wall. Some fit together like a jigsaw puzzle. Others are big and bulky. But do we need all of that? I need my sawhorses to be strong, but not too heavy so they remain easily portable. They need to be able to take a beating from a circular saw. They need to be relatively small so they take up less space when stored. Oh, and they need to stack so that multiple saw horses only use one footprint. So what I have are, in my opinion, the best saw horses. It’s an I-beam style saw horse which doubles the sacrificial surface life as well as gives an incredible amount of clamping area. To build one set (2) you will need the following:
- five 8′ 2x4s
- 44 3″ screws
- powered or hand saw
Cut all of your materials to length. This is too simple of a design to make a cutting diagram so the cuts are as follows:
- 10 pieces at 30″ long (legs and center of I-beam)
- 4 pieces at 32″ long (top and bottom of I-beam)
To make the I-beam arrange one 30″ piece vertically between two 32″ pieces as shown and secure them with three 3″ screws on top and bottom. Make sure to center the 30″ board so that there is a 1″ overhang on both sides. On previous saw horses I made all 3 pieces of the beam the same length. You wouldn’t believe how many times I wished the middle board was shorter so I could put a clamp right on the end.
Lay the beam flat and start screwing two 30″ legs down. The legs will fit into place on an angle. Make sure you position the legs so that they are even with the center 30″ piece so you are not covering up the end clamping area. In this diagram, the lower 2 screws should be screwed in vertically and the other two screws should be screwed in at an angle to go directly into the bottom piece of the I-beam.
Flip the assembly over and secure the other two legs in the same way.
That’s it. As you can tell these are incredibly easy to make. They also stack for easy storage that only takes up one footprint.
As you can tell I get a lot of use out of my sawhorses. Here are a few pics of them in various applications in my shop followed by a short video covering the build.