How to Make a Portable Saw Horse

Written by finn mccuhil
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How to Make a Portable Saw Horse
Storing sawhorses can be a problem in a small shop. (Jupiterimages/ Images)

A sawhorse is a basic requirement for any woodworking shop. Unfortunately, finding the space to store them when they're not in use isn't easy. Open space is often at a premium even in larger shops. Portable sawhorses can be a practical answer to storage problems. They are simple to build with materials available from most home improvement stores and a few basic tools.

Skill level:

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Things you need

  • 3 -- 8-foot 2-by-4s
  • Measuring tape
  • Saw
  • Set of sawhorse brackets
  • Drywall screws
  • Drill with driver bit

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  1. 1

    Measure and cut two 2-by-4s into 4-foot lengths. These four pieces will become the legs for the sawhorse.

  2. 2

    Measure and cut the remaining 2-by-4 into two 4-foot lengths. One of these lengths is used for the top crosspiece that connects the two sets of legs. The second 4-foot section can be used as an optional cap for the crosspiece.

  3. 3

    Insert one 4-foot leg section into each of the bracket's leg openings.

  4. 4

    Secure the leg sections into the bracket with drywall screws. Use a drill with a driver bit to insert a screw into each of the predrilled holes in the bracket.

  5. 5

    Repeat Steps 3 and 4 for the remaining bracket.

  6. 6

    Place the crosspiece into the jaws on the brackets. The crosspiece should extend 6 inches past the outside of each bracket.

  7. 7

    Spread the legs attached to the brackets to lock the crosspiece in place. When you are finished working on the sawhorses, simply push the legs back together, remove the crosspiece and store the disassembled sections in a convenient location.

Tips and warnings

  • Make a wider work surface on your sawhorse by attaching the remaining section of board to the top of the crosspiece. Center the wide surface of the board on top of the crosspiece and fasten it in place using six evenly spaced 2 ½-inch drywall screws.
  • Not all sawhorse brackets are created equal. Heavy gauge steel brackets will be more stable and last longer than less expensive ones made from tin or plastic.

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