Heavy-Duty 2x4 Sawhorses (Pair) — board plan

What to buy, and which parts come off which board.

Buy 8 boards at 8 ft.

1 1/2" × 3 1/2" — 2x4, 8 ft

6 boards · 21.8 board feet (includes 15% for knots and defects) · 92% of the boards you buy used

Board 1 · 4 3/4" left over
32"32"25 7/8"
1. Top and bottom support rails — 32"
2. Top and bottom support rails — 32"
3. Legs — 25 7/8"
Board 2 · 4 3/4" left over
32"32"25 7/8"
1. Top and bottom support rails — 32"
2. Top and bottom support rails — 32"
3. Legs — 25 7/8"
Board 3 · 4 3/4" left over
32"32"25 7/8"
1. Top and bottom support rails — 32"
2. Top and bottom support rails — 32"
3. Legs — 25 7/8"
Board 4 · 6 1/8" left over
25 7/8"25 7/8"25 7/8"10 3/4"
1. Legs — 25 7/8"
2. Legs — 25 7/8"
3. Legs — 25 7/8"
4. Bottom foot pieces — 10 3/4"
Board 5 · 4 1/4" left over
25 7/8"25 7/8"19 1/4"19 1/4"
1. Legs — 25 7/8"
2. Legs — 25 7/8"
3. Center pieces — 19 1/4"
4. Center pieces — 19 1/4"
Board 6 · 23 5/8" left over
19 1/4"19 1/4"10 3/4"10 3/4"10 3/4"
1. Center pieces — 19 1/4"
2. Center pieces — 19 1/4"
3. Bottom foot pieces — 10 3/4"
4. Bottom foot pieces — 10 3/4"
5. Bottom foot pieces — 10 3/4"

3/4" × 2 1/2" — 1x3, 8 ft

2 boards · 2.0 board feet (includes 15% for knots and defects) · 71% of the boards you buy used

Board 1 · 27 1/2" left over
33 5/8"33 5/8"
1. Diagonal cross pieces — 33 5/8"
2. Diagonal cross pieces — 33 5/8"
Board 2 · 27 1/2" left over
33 5/8"33 5/8"
1. Diagonal cross pieces — 33 5/8"
2. Diagonal cross pieces — 33 5/8"

Cuts are listed longest-first, which is how they should be made: the awkward pieces get placed while there is still board to place them on. The layout assumes one end of each board is squared off (1") and that every cut costs 1/8" of kerf — the reason six 16″ parts do not fit on a 96″ board.

1 1/2" × 3 1/2" — 2x4, 8 ft

Board 1 · 4 3/4" left over

Board 2 · 4 3/4" left over

Board 3 · 4 3/4" left over

Board 4 · 6 1/8" left over

Board 5 · 4 1/4" left over

Board 6 · 23 5/8" left over

3/4" × 2 1/2" — 1x3, 8 ft

Board 1 · 27 1/2" left over

Board 2 · 27 1/2" left over