Easy Heavy Duty 2x4 Sawhorses

Submitted by Ana White on Mon, 04/27/2015 - 10:02
Difficulty
Beginner
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The ultimate sawhorses! Easy to make, plans by ANA-WHITE.com

We've just got a few days left in this month's #GetBuilding2015 Challenge - to spruce up your #BuildCave!

And let's not forget that someone is going home with a Kreg Foreman Pocket Hole Machine!!!  Could be you!

 

I've been working on making my own BuildCave a little more organized and nicer over the last year.  One of the more recent projects I took on was new sawhorses!

Of course we have lots of sawhorses, but we needed extreme heavy duty ones that could support huge timbers that we are prepping for the cabin.  So I came up with this design.

So this is the other side of the shop where all the work gets done ..... those sawhorses really stood up to the job, even when huge beams were placed on top and chiseled into, they stood solid!  

We loved these sawhorses so much that I actually made no less than six of them!  I think they are the perfect design for the workshop with a wide top, cross bracing horizontally to prevent side to side movement, and splayed legs for back and forth stability.  I love them.

I put together a quick little video on how this sawhorse was made too, check it out!

Plans follow!

Ana

Dimensions
Dimensions shown above

Preparation

Shopping List

FOR TWO SAWHORSES
4 - 2x4s @ 8 feet long
2 - 1x3s @ 8 feet long

Common Materials
1 1/2 inch screws
2 1/2 inch screws
Cut List

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)

Tools
Tape Measure
Speed Square
Pencil
Safety Glasses
Hearing Protection
Drill
Miter Saw
General Instructions

Please read through the entire plan and all comments before beginning this project. It is also advisable to review the Getting Started Section. Take all necessary precautions to build safely and smartly. Work on a clean level surface, free of imperfections or debris. Always use straight boards. Check for square after each step. Always predrill holes before attaching with screws. Use glue with finish nails for a stronger hold. Wipe excess glue off bare wood for stained projects, as dried glue will not take stain. Be safe, have fun, and ask for help if you need it. Good luck!

Instructions

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 Instructions
Preparation Instructions
Fill all holes with wood filler and let dry. Apply additional coats of wood filler as needed. When wood filler is completely dry, sand the project in the direction of the wood grain with 120 grit sandpaper. Vacuum sanded project to remove sanding residue. Remove all sanding residue on work surfaces as well. Wipe project clean with damp cloth.

It is always recommended to apply a test coat on a hidden area or scrap piece to ensure color evenness and adhesion. Use primer or wood conditioner as needed.
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Comments

x-ray_dren2005

Sun, 07/12/2015 - 04:40

I had the same problem. I sat with a pen, paper, and calculator for an hour trying to configure this project into 4 - 2x4 @ 8ft. I thought maybe it was a typo and it was 10ft 2x4's, but that didn't work either. Back to the store I go!

NMexFisher

Fri, 04/01/2016 - 11:01

Hi Ana, I've been looking at various saw horse designs and I really like yours. I wanted to point out that because you have left the slot along the top, you could use it to place different accessory pieces into like a makeshift shelf or boards with carpet on them that would protect your workpiece. I really enjoy checking out all the projects you've accumulated. I wish I had more time to build some of your projects. Thank you. - Mario

jacksdad3

Wed, 06/15/2016 - 05:13

Ana, these are terrific saw horse plans!  So many plans are overly complex or just too darned rickety! 

I am recently retired and need a couple of sturdy saw horses for my "shop" at our 5th Wheel RV site.  I will use your plans to get my "shop" started. 

Debbie742

Wed, 02/22/2017 - 04:01

Thanks for the plans, and i'll be building these pretty quick. Is the drill you are using the impact drill, or just a normal drill? And which drill do you find you use most?  Also, you mention counter height saw horses??  What height would that be, and for what purpose?  AND do you have a preference of self tapping screws??  Sorry for all the questions, but I might as well get this build right the first time eh!!  Thanks bunches!!

Debbie

Debbie742

Sun, 02/26/2017 - 11:08

What is the difference between the counterheight and table height? And what would the adjustments be??  Also, which drill are you using, and is it the spax screws that you used?? 

thanks bunches.  I did post a question a few days ago, but it didn't post...I don't think.

Debbie.

RobbieOrr

Thu, 08/15/2019 - 20:16

Thanks for the plans- I saw several and these were far and away the simplest. I modified them in a few ways:

1. Shortened it to 24” as I am using them for slabbing logs. 

2. Made them 56” wide to be able to roll the logs for debarking. 

3. I allowed for about 6” overhang beyond the legs to be able to keep the cross braces at 48” and add a pivoting stop block on one end. 

4. I used pressure treated lumber and exterior wood glue as they will be spending a lot of time outside. 

 

I have photos to share if you’d like.