Free outdoor sawhorse bench plans!
5 - 2x4 @ 8 feet long
1 - 2x6 @ 8 feet long
4 - 2x4 @ 15 1/2" long (both ends cut at 10 degree double bevel ends ARE parallel)
2 - 2x4 @ 15 1/4" long, both ends cut at 10 degree ANGLE off square, ends ARE parallel (not a double bevel like the end legs)
3 - 2x4 @ 5 5/8" long (longest point, both ends cut at 10 degrees off square, ends NOT parallel)
3 - 2x4 @ 12 1/2" long (both ends cut at 45 degree bevel, ends NOT parallel)
2 - 2x4 @ 88"
1 - 2x6 @ 88"
2 - 2x4 @ 32 1/4" (one end cut at 25 degree bevel, other at 17 degree bevel, cut in same bevel direction)
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!
A Kreg Jig is highly recommended for construction of this project.
Build your two end leg sets using 1 1/2" pocket holes and 2 1/2" pocket hole screws and glue.
You can also build the center leg (see last diagram) now.
Attach legs to headers with 1 1/2" pocket holes and 2 1/2" pocket hole screws and glue.
Build your bench top with pocket holes first (unles you are using outdoors and will require water drainage, then leave spacing between boards to allow water to drain).
Then attach legs to the underside of bench top. Overhang is 10 1/4' from ends (see diagram 5)
You can either build the entire center leg (see last diagram) and attach you did the outside legs, or attach middle header here.
Attach center leg to center.
For additional support, the center leg could also be tied into the outside legs.
Whitney also framed the bench top out for additional support and looks - check out how she did that here.
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.