How to Make a Saw Horse | DIY Project

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While working on a specific project, you may need a make-shift table to use when sawing, painting, storing some of your tools or use as an extra workbench to help make your work more convenient and productive. This is where sawhorse became a necessity. Because of its handy and versatile uses, you might need more than one to use when working on your projects at home. With that in mind, you might be asking yourself this question, how to make a saw horse? And since it is easy to do, that wouldn’t be a problem.

This article will walk you through the steps in making the simplest but durable and stable sawhorse for your needs. After this, you will be able to make few pieces to stack and use for different purposes.

What you will need to follow this tutorial


  • Wood

For this tutorial, we will be using few pieces of 8’ 2x4 wood which will be later cut into 32” and 30” for the I-beam, sawhorse legs and stringers.

  • Screw

This is to hold the pieces together securely. We will need several of this to ensure the stability of the sawhorse.

Optional:

  • Stain, Paint

You may want to put some polish and finishing touches on your sawhorse. It is neither required nor necessary as most woodworkers use it already as it is since it will be only be stacked on their work stations and may be subjected to rough and heavy duty jobs.

Tools you need to prepare:

  • Miter Saw or hand saw
  • Drill
  • Tape Measure
  • Pencil / Wood Marker

Saw horses has many uses, thus having one will greatly help you with your wood projects and increase your productivity and efficiency when working. Many would opt to build one because it is more economical, convenient and easy to do. And most wood workers typically use more than one of it because it is flexible and there are basically a lot of things you could think to use it for.

Before we proceed with the steps on how to make a basic sawhorse, allow me to share these following pro tips:

  • Consider the size of the sawhorse

Take note of the size of the sawhorse you will make, as it should be able to meet your needs. Of course, if you are taller and over 6-feet, you may want to adjust the length of it to your comfort level.

  • Make it simple but robust

Sawhorse is not much of a decorative piece, as it is more heavily weighted on functionality. Make sure that when you build one, materials are solid and construction is sturdy for frequent and long-time use of it.

  • You can add extra details

For added use, you can build shelves in it for extra storage space.

Step by Step Instructions


Sawhorses are typically easy to make because its shape and form is pretty basic. If you look at it, there are only two main parts: the beam and the legs. What you have to be very keen about though, is making sure it is durable and stable as it is primarily use for support on several woodworking jobs especially sawing woods.

Once all materials are set, you can proceed with starting to build the sawhorse using these following steps and processes.

Step 1: Cut materials to length


Making your own sawhorse means you will be able to customize it depending on the size you want that will suit your needs.

The first step is cutting your 2x4s into your desired length. For this tutorial, we will be cutting it to 30” and 32” long. This will be for both the beams and the legs of the sawhorse.

Step 2: Gluing the Lumber Pieces


Making the I-Beam will require one piece of 30” and two of the 32” wood. Stack the 30” vertically between the two 32” and secure them tightly with the screws. Make sure to arrange the 30” at the very center of the other two. It will show a one-inch overlap in both sides.

And to make sure it is securely and durably fasten, screw them on top and bottom, at both ends and at the middle of the beam.

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Step 3: Attach the legs


We will be using 30” of wood for the legs. To attach it to the beam, first lay the I-Beam on its side. Using one 30”, screw it tightly just under the end of the top beam, which also means placing it evenly on the center piece.

Screw the leg piece into the lower beam twice and on the center of the beam two times as well to keep it from wobbling or shaking. The two screws at the middle piece should be angled to go directly to the bottom part of the I-Beam.

Repeat the same process on the other end, then flip the beam over to attach the other two legs on the other side.

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Once all legs are properly and securely attached, try standing the beam and check for any wobble and that all screws are accurately tucked in. It is important to make sure that the finish output is durable and solid for heavy duty and regular use.

Step 4: Add stringers to stabilize the legs


The addition of this stringer will be dependent on you as some can do without it. To do this, cut two of the 32” for each side. Measure about 10” from the end of each of the legs and mark it down for reference. Attach one 32” on one side of the sawhorse placing them across the mark. The end should be aligned on the end side of each leg. Do the same thing on the other side.

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Step 5: Build an end stringer


Measure the distance of both ends of the sawhorse that is directly aligned to the attached stringers. Cut the size on your 2x4 and screw it to both legs. Repeat the process of the other side.

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Once done, your sawhorse is now ready for use. You can also make more of this sawhorse and stack it together to increase length and performance.

Conclusion


After going over each of the steps, did you find it enjoyable and easy to do? Were you able to gather some ideas and take note of the processes?

Sawhorse is a familiar figure in every woodworker’s work stations because of its several uses. You can use it as a table base, or as a plank support for sawing of wood, among other things. It is because of its versatility that makes it an essential woodworking equipment. And it is because of this reason I find it important to be able to know how to make one at home. Aside from the fact that it will save you money, the steps are made to be easy to follow and you can make as many as you need with only pieces of wood and screws required.

What other uses do you have with your sawhorse? With a rather basic form and features, some would add few details in it like shelves for storing some stuffs. Comment your thoughts and ideas below. And if you find this tutorial worthy of your time, share and tell your friends.

  • July 8, 2017
  • DIY
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