Sawhorses: The Underrated Workstation Foundation
Every workshop and jobsite needs a pair of reliable sawhorses. They support sheet goods during cutting, serve as an elevated work surface, hold doors during fitting, and carry assembled components between work areas. A well-built pair lasts decades. Here’s how to build a classic folding sawhorse that stores flat and weighs under 15 lbs.
Materials for a Pair of Sawhorses (30″ height)
- 2×4 lumber — 4 pieces at 48 inches (legs), 2 pieces at 36 inches (top beam)
- 1×6 lumber — 4 pieces at 22 inches (leg gussets for stability)
- 3-inch exterior screws — 50 count
- 1-5/8-inch screws — 30 count for gussets
- Optional: folding sawhorse brackets (Telpro or Stanley) for a collapsible design
The Folding Bracket Option
If you want folding sawhorses, buy a set of folding metal sawhorse brackets (around $15/pair). Cut four 2×4 legs at 34 inches, cut a 2×4 top beam at 36 inches, and assemble: the brackets hold everything at the correct angle and allow the legs to fold flat for storage. This approach takes 30 minutes and produces a functional sawhorse, though it’s less rigid than a fully built version.
Building Fixed Sawhorses: Step by Step
For a solid fixed sawhorse: cut the top beam to 36 inches. Set a bevel gauge to 15° — this is the leg splay angle. Cut both ends of each leg at 15° so they splay outward and sit flat on the floor. Mark leg positions on the top beam — approximately 3 inches from each end. Drive 3-inch screws through the beam into each leg top at the marked positions, two screws per leg for rigidity.
Adding Gussets for Rigidity
Cut 1×6 gusset boards to fit from the top beam to the leg surface. These triangular gussets dramatically increase lateral rigidity — a sawhorse without gussets will rack under side load. Attach with 1-5/8-inch screws, 3 per gusset. Add a lower stretcher between legs on each side (a 2×4 screwed horizontally between the legs at mid-height) for additional stability under heavy loads.
Optimal Height
Standard sawhorse height is 27–30 inches for cutting work (comfortable working position for most adults). For use as an assembly table, 34–36 inches reduces back strain. Match height to your most common use. If building multiple pairs, build them all to the same height for a level assembly surface when spanning across two pairs.
Finishing Touches
Sand cut edges smooth to prevent splinters. Add a strip of carpet or foam padding to the top beam for finishing work where surface marring matters. Paint or seal with a quick coat of exterior primer — bare wood sawhorses absorb moisture and become heavy over time.
Find all the lumber, screws, and power tools for this build at Pro Tools Hub.
