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Each leg set here starts as a small T: a short bottom foot piece screwed to a vertical center piece, aligning the foot's center on the center piece so it sits balanced under the leg. From there, attach the angled 2x4 legs to the bottom foot piece 8" up from the bottom, then attach the tops of the same legs to the center piece — build two identical leg sets per sawhorse.
Join the two leg sets with the top 2x4 running the length of the sawhorse plus a bottom support 2x4 underneath, both attached with screws. The diagonal 1x3 cross pieces go inside the sawhorse last, screwed in place to keep the whole thing from racking side to side under load — this is what turns two wobbly leg sets into a genuinely heavy-duty stand. Build two sawhorses the same way.
| Item | Qty |
|---|---|
| 2x4, 8 ft | 4 each |
| 1x3, 8 ft |
| 2 each |
| Self-tapping wood screws, 2-1/2" | 40 each |
| Self-tapping wood screws, 1-1/2" | 16 each |
Overall cost: $. Lumber prices vary by region, species, and season, so we give a band rather than a figure we would only be pretending to know.
| Part | Qty | T × W × L |
|---|---|---|
| Bottom foot pieces2x4, 8 ftBoth ends cut at 15° off square, ends not parallel, longest point measurement. | 4 | 1 1/2" × 3 1/2" × 10 3/4" |
| Center pieces2x4, 8 ft | 4 | 1 1/2" × 3 1/2" × 19 1/4" |
| Legs2x4, 8 ftBoth ends cut at 15° off square, parallel, long point to short point measurement. | 8 | 1 1/2" × 3 1/2" × 25 7/8" |
| Top and bottom support rails2x4, 8 ft | 6 | 1 1/2" × 3 1/2" × 32" |
| Diagonal cross pieces1x3, 8 ftBoth ends cut parallel at 18° off square, long point to short point measurement. | 4 | 3/4" × 2 1/2" × 33 5/8" |
Buy 8 boards at 8 ft.
6 boards
2 boards
Assumes 8 ft stock, a 1/8" saw kerf, and buying each part at its own width. Change the board size or kerf on the full board plan →
Attach a bottom foot piece to a center piece with 2-1/2" screws, aligning the center of the bottom piece with the center piece.
Attach the legs to the bottom foot piece with 2-1/2" screws, 8" up from the bottom of the leg. Attach the tops of the legs to the center piece. Build two leg sets per sawhorse.
Attach the top support rail and bottom support rail to both leg sets with 2-1/2" screws.
Place the diagonal cross pieces inside the sawhorse and attach with 1-1/2" screws. Repeat all steps to build the second sawhorse.
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