Easy Heavy Duty 2x4 Sawhorses

heavy duty easy to build sawhorse plans
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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 plans by ANA-WHITE.com

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Heavy Duty - Used for over 10 years in construction

We built these sawhorses for a timber framing project.  They have held up well and we are still using them today.  There is absolutely no wobble in the sawhorses, and they are as strong as day 1!

 

Watch the Quick Build Video

Here is a quick build video of building the sawhorses.

Free Plans to Build Your Own Heavy Duty Sawhorses

Ready to build your own?  The free plans are below.  Please send in photos if you build, we love seeing your results.

Dimensions
heavy duty sawhorse plans
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.

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. 

rdgsc

Wed, 09/23/2020 - 10:46

Hey Ana:

I really like the design of your sawhorses: simple, sturdy, and easy to build. I believe that you mentioned in your video that you built another taller set. If so, did you just change the length of the legs? And, did anything else change?

Best,

Linda K Adkins-Smith

Fri, 10/15/2021 - 08:44

Girl you truly inspire me and others. I have plans now to design me a workshop. I have used your site for several projects and they have all turned out. You just make it so simple. Except I still have those dang drawer slides that are truly a pain to get to fit and work. I even ordered a Kreg drawer kit and still have problems. I figure practice makes perfect. Thank you for all you do to help us

Frequently Asked Questions

Wood Questions

What kind of wood should I use?
Most of our plans use standard construction lumber like pine or fir. It's affordable, easy to work with, and easy to find. It's also rapidly renewing and biodegradable, so a great eco friendly choice!

Can I use hardwoods instead?
Yes—just keep in mind they're heavier, cost more, and can be tougher on tools and harder to join together and finish. I recommend not tackling a hardwood project until after you have built several softwood projects.

What if my boards are warped?
Choose the straightest boards at the store. You can often work around slight warps by cutting them into shorter pieces.

What wood should I use for outdoor furniture?
Use red-toned or pressure-treated 2x lumber for framing, and cedar or cedar fence pickets for the decking. Outdoor furniture should be built like a deck—your local home center can help recommend the right wood for your climate.

Will my wood move or warp after I build?
Potentially, especially in humid climates. Let your wood acclimate indoors before building. Once acclimated and kept in a stable environment, movement should be minimal. Remember, most houses are built using framing lumber - it's all about keeping moisture down indoors.

Cutting Questions

Do I need a miter saw?
A miter saw is great, creating fast, safe, and precise cuts, even for beginners. But most plans can be built with a circular saw and a straight edge. If using a circular saw to cut, take time to practice, and get good at making cuts, before cutting your project boards.

How do I get clean cuts with a circular saw?
Clamp your board, measure twice, cut slow, and use a sharp blade. This takes practice, so spend some time making cuts. I go through becoming proficient at freehand cutting in my course, it is worth taking if you want to master this skill.

Will the store cut my wood?
Yes—most stores will do rough cuts to help you transport your materials home. But from store to store, the quality of cuts could greatly vary.

Joinery Questions

What screws should I use?
We recommend star-head self tapping screws for framing, most common sizes are 2-1/2", 1-3/4". Pre-drill if close to the edge or you find your wood is splitting.

Do I have to use pocket holes?
Pocket holes are the cheapest, easiest and fastest way to do some joints - like edge to edge or a hidden fastener joint. There are other methods, but these can be time consuming and expensive. We recommend using pocket holes as indicated in plans for best results.

How do I keep things square?
Use a speed square and measure diagonals after each step. Always clamp joints before screwing to keep them tight and flush.

Finishing Questions

Stain or paint before or after building?
A quick sand before and a full finish after gives the best results. Pre-finish if you're doing two-tone or detailed finishes.

What type of finish?
Use oil-based or water-based stain. For paint, cabinet-grade latex or enamel works great. High use surfaces on indoor projects should get a coat of polyurethane, I recommend a Helsman or Spar or other flexible poly that won't crack or peel with wood movement. For exterior projects, use a finish suitable for exterior fences.

How to get a smooth finish?
Start with a well sanded project. Sand between coats (220 grit), wipe clean, and apply light coats with a foam brush or roller.

Plan Questions

Can I change the size?
Many people do, and that's the great thing about building your own furniture! But do keep in mind going bigger might mean more supports are required, and often plans are optimized for minimal material waste.

Are these beginner-friendly?
Yes—plans are written with simple tools and clear steps in mind, with every effort to make plans as simple as possible.

Can I sell what I build?
Absolutely! Just don’t resell or repost the plans themselves.

General Questions

What tools do I really need?
A drill, circular saw, tape measure, square, and a few clamps will get you through most projects.

Do I need a workshop?
Nope! A driveway or small patio is plenty to get started, just make sure you have a level place to work. If you find you are building several projects a year, creating a small workbench is a great way to store tools and have a dedicated workspace.

What if I mess up?
Wood filler, sanding, or flipping boards goes a long way. Mistakes are part of the process!

What can I do to make my projects look more professional?
Start with straight boards, make accurate cuts, clamp all joints, and line up everything neatly. Sand thoroughly, use a neutral finish, and apply it in light coats for a clean look.

I've never built anything before. Where should I start?
Start with a few smaller softwood projects to get hands-on experience. Or if you're tackling a big project, buy a little extra lumber and practice your cuts and joints first. If possible, work with someone who has a bit of experience.

Care & Maintenance

How long will my furniture last?
With good joinery and regular care, your DIY furniture can last for decades. I have pieces in my own home that are over 20 years old and still going strong! One of the best parts about DIY furniture is that it’s easy to repaint, refinish, or repair—so your projects can grow and adapt with you.

How should I care for outdoor furniture?
Lightly pressure wash or hose it down once or twice a year. Tighten screws and reapply finish as needed to protect it—just like a deck or fence. A little upkeep goes a long way in extending the life of your furniture.

How about indoor furniture?
Regularly dust or wipe with a damp cloth. If it starts to look worn, a light sanding and touch-up paint or stain can refresh it in no time. DIY pieces are meant to be durable and fixable—so don’t be afraid to give them some love now and then.

Want to Build with Confidence?

Check out my ebook: 12 Skills to Build Your Own Furniture
It walks you through the core skills every builder needs—measuring, cutting, joinery, and finishing—so you can build beautiful furniture that lasts.

Still Have Questions?

Email us anytime at [email protected] and we’ll be happy to help!