Easy Heavy Duty 2x4 Sawhorses
The ultimate sawhorses - easy to build and extremely sturdy. I've been using these same sawhorses for over ten years. If you are looking for a long term, heavy duty sawhorse, these are the ones to build. You'll just need two 2x4s and a 1x3 furring strips and some screws to build - no special brackets! Free.
Dimensions
Use the size-specific shopping and cut lists below.
What you need
- 4 - 2x4s @ 8 feet long
- 2 - 1x3s @ 8 feet long
FOR TWO SAWHORSES
- 4 - 2x4 @ 10-3/4" (both ends cut at 15 degrees off square, ends are NOT parallel, longest point measurement)
- 4 - 2x4 @ 19-1/4"
- 8 - 2x4 @ 25-7/8" (both ends cut at 15 degrees off square, ends ARE parallel, long point to short point measurement)
- 6 - 2x4 @ 32"
- 4 - 1x3 @ 33 -5/8" (both ends cut parallel at 18 degrees off square, long point to short point measurement)
FOR TWO SAWHORSES
- measuring tape
- square
- pencil
- safety glasses
- hearing protection
- drill
- compound miter saw
Step by step
Step 1
Attach with 2-1/2" screws bottom piece to center piece, aligning center of bottom with center piece.
Step 2
Attach legs to bottom center piece with 2-1/2" screws, 8" up from bottom of leg. Attach with 2-1/2" screws tops of legs to center piece. Build two of these leg sets per sawhorse.
Step 3
Attach with 2-1/2" screws the top 2x4s and bottom support 2x4.
Step 4
Place the cross pieces inside the sawhorse and attach with 1-1/2" screws (or similar size).
Finishing
Sand all surfaces, starting with a medium grit and finishing with fine. Wipe off the dust, fill any holes or gaps with wood filler, and sand smooth once dry. Apply primer if you're painting, then finish with your choice of paint or stain and seal with a durable clear topcoat. For outdoor projects, use exterior-rated primer, paint or stain, and sealer so the piece stands up to the weather.
