This pair of sawhorses requires nothing but 2 x 4s and the design allows you to stack them conveniently out of the way when not in use. If you don't have enough 2 x 4s in your scrap pile to build this, it will cost less than $20 in wood and screws to buy everything you need.
This style of sawhorse is popular on construction sites everywhere and can be built using nails or screws. We first saw this design used by Mark Clement of My Fix It Up Life and we like the updated version from Jay Bates which allows for clamps to be used on the ends.
We used a miter saw to trim the wood but any saw will do. A measuring tape, pencil, drill/driver, and 3" deck screws are the only other tools you'll need for assembly. They shouldn't take longer than an hour to build but they'll last for years. If the top gets cut-up or damaged, just replace it with another 2x4.
1. Cut List
There are only two lengths of lumber you need for this project. 10 pieces of 30-inch 2 x4s for the center of the I-beam and the legs, and four pieces of 32-inch 2 x 4s for the top and bottom of the I-beam.
If you are buying new stock, you can cut all of the above from just five pieces of 8-foot 2 x 4s which are available at any Home Depot or Lowe's.
2. Build the I-Beams
The I-beam supports the legs and provides a work surface. Stand a 30-inch 2 x 4 on its side and center a longer 32-inch board on top. It should overhang an inch on each end. Drill three pilots holes and attach the pieces using the deck screws. Flip the piece over and repeat the process. The second I-beam should go faster since you've done it before.
3. Attach the Legs
After the legs are attached your sawhorses are ready for use, or just stack them away for storage.
4. Sawhorse Mods
Tacking carpet onto the top of the sawhorse can prevent your new 'horses from scratching doors, surfboards, or anything else with a fragile finish. You can also paint and seal your sawhorses to finish the look.
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