How to Build a Sawhorse

This step by step diy woodworking project is about how to build a sawhorse. Therefore, if you want to add several sawhorses to your shop, we recommend you to pay attention to this project, as it will show you everything you need to know about sawhorses. Generally speaking, it is a better idea to build several of these sawhorses, as you will most certainly need several when building or cutting something.

Make sure you invest in high quality materials, such as pressure-treated lumber, cedar, pine or redwood. Take accurate measurements and use a professional saw to get the job done. Always align the components at both ends before drilling the pilot holes and inserting the galvanized screws, in order to prevent the wood from splitting. Use waterproof glue to reinforce the joints. See all my Premium Plans HERE.

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How to Build a Sawhorse

Building a sawhorse

Cut & Shopping Lists

• A – 4 pieces of 2×4 lumber – 24″ long LEGS
• B – 1 piece of 1×4 lumber – 8 1/4″ long BRACES
• C – 1 pieces of 2×6 lumber – 48″ long TOP

• 1 piece of 2×4 lumber – 8 ft
• 1 piece of 1×4 lumber – 1 ft
• 1 piece of 2×6 lumber – 4 ft
• sawhorse brackets
• 2 1/2″ screws
• 1 5/8″ screws
• 1 1/4″ screws
• wood filler
• wood glue
• stain/paint

Tools

 Hammer, Tape measure, Framing square, Level

 Miter saw, Drill machinery, Screwdriver, Sander

 Safety Gloves, Safety Glasses

Time

 One day

Related

• Storage Shelves Plans
• Workbench Plans

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Building a sawhorse

Building the legs

The first step of the woodworking project is to build the legs of the sawhorse. As you can easily notice in the diagram, we recommend you to cut both ends of the lehs at 15 degrees. Smooth the cut edges with sandpaper and remove the residues with a vacuum.

Mark the cut lines to the top of the legs and get the job done with a circular saw. Take accurate measurements for a professional result.

Building the top slat

The next step of the woodworking project is to build the top of the sawhorse. As you can easily notice in the plans, we recommend you to cut the 2×6 lumber at the right size, after taking accurate measurements.

In addition, we recommend you to create four recesses to the slat, in order to fit the legs into place. Use a chisel to clean the recess and smooth everything with great care using a sandblock.

Fitting the legs to the saw

The next step of the project, we recommend you to attach the wooden legs to the top of the sawhorse. Drill pilot holes through the top of the legs and secure them to the board using 2 1/2″ screws.

Fitting the braces

In order to add rigidity to the sawhorse, we recommend you to attach 1×4 braces to the legs. As you can easily notice in the diagram, we recommend you to cut both ends of the braces at 15 degrees. Smooth the cut edges with sandpaper and remove the residues with a vacuum. 

Drill pilot holes through the braces and secure them to the legs with 1 1/4″ galvanized screws. Add glue to the joints and remove the excess with a damp cloth.

How to build a sawhorse

After assembling the wooden sawhorse we recommend you to check if the components are locked together properly. Insert the galvanized screws properly, making sure they are at the same level with the wooden surface.

Top Tip: Don’t forget to take a cover the components with paint, if you want to enhance the look of the sawhorse and to make it stand out. Use glue to lock the components into place.

This woodworking project was about how to build a sawhorse. If you want to see more outdoor plans, we recommend you to check out the rest of our step by step projects.

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