Sawhorse Outdoor Bench — board plan

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

Buy 6 boards at 8 ft.

1 1/2" × 5 1/2" — 2x6

1 board · 5.8 board feet (includes 15% for knots and defects) · 93% of the boards you buy used

Board 1 · 6 7/8" left over
88"
1. Top center board — 88"

1 1/2" × 3 1/2" — 2x4

5 boards · 16.2 board feet (includes 15% for knots and defects) · 82% of the boards you buy used

Board 1 · 1 1/8" left over
88"5 5/8"
1. Top rails — 88"
2. Leg feet/tops — 5 5/8"
Board 2 · 1 1/8" left over
88"5 5/8"
1. Top rails — 88"
2. Leg feet/tops — 5 5/8"
Board 3 · 2" left over
32 1/4"32 1/4"15 1/2"12 1/2"
1. End aprons — 32 1/4"
2. End aprons — 32 1/4"
3. End legs — 15 1/2"
4. Trestle gussets — 12 1/2"
Board 4 · 4 3/4" left over
15 1/2"15 1/2"15 1/2"15 1/4"15 1/4"12 1/2"
1. End legs — 15 1/2"
2. End legs — 15 1/2"
3. End legs — 15 1/2"
4. Center legs — 15 1/4"
5. Center legs — 15 1/4"
6. Trestle gussets — 12 1/2"
Board 5 · 76 5/8" left over
12 1/2"5 5/8"
1. Trestle gussets — 12 1/2"
2. Leg feet/tops — 5 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" × 5 1/2" — 2x6

Board 1 · 6 7/8" left over

1 1/2" × 3 1/2" — 2x4

Board 1 · 1 1/8" left over

Board 2 · 1 1/8" left over

Board 3 · 2" left over

Board 4 · 4 3/4" left over

Board 5 · 76 5/8" left over