How to make a Sawhorse
Throughout my building career I have always had a couple of these sawhorses handy.
You can work on them, sit on them, stack on them, stand on them. In fact, I can't imagine doing a job without them.
I probably made my first one some 45 years ago and the design and method of making is still pretty much the same.
Made properly, they are a very solid work horse.
No power tools needed
All you need is a handsaw, hammer, chisel, and an adjustable bevel.
Even though the making of this sawhorse requires the odd compound angle cut (cutting two different angles at the same time, i.e., an angle across the width as well as the thickness of a piece of wood), it can be built without the use of any power tools whatsoever.
The measurements throughout this project are given in both standard (inches) and metric (mm).
The standard measurements are given first followed by the metric measurements in brackets ( ). For example: 2x4 (100mm x 50mm).
The standard measurements are best suited to North America and the Metric measurements are best suited to Australasia.
The inch sizes given in this project do not convert exactly to their corresponding metric (mm) equivalents, so use one or the other.
The wood sizes
There are three wood sizes required for this project and they are all common stock sizes.
2x6 (150mm x 50mm) for the beam, 2x4 (100mm x 50mm) for the legs, and a bit of 3/4" (18mm) thick plywood or board for the leg braces.
Of course the sizes mentioned above are the nominal sizes (in name only). The real (actual) sizes of the wood will be a little less once the wood has been dimensioned (dressed, planed).
You will need...
• For the beam - I piece of 2x6 (150mm x 50mm) wood 44" (1000mm) long.
• For the legs- 4 pieces of 2x4 (100mm x 50mm) wood 27" (675mm) long.
• For the braces - 2 piece of 3/4" (18mm) thick plywood at least 6" (150mm) wide x 24" (600mm) long.
• 24 galvanized flat-head nails 2 1/2" (60mm) long,
• and a bit of glue.