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A single sawhorse is easy; a pair that nests together for storage without metal brackets takes a little more planning. The trick is entirely in the dimensions: one horse's I-beam is built 2" longer than the other, with its legs set close to the ends, while the shorter horse's legs sit 1" in from its ends — the size difference is exactly what lets one slide inside the other when they're not in use.
Each sawhorse's spine is a sandwiched I-beam rather than a single board, which is what gives it the stiffness to support a sheet of plywood or a long board without sagging in the middle.
A 20° bevel on the feet is optional but worth adding if the horses will live on a hard shop floor — it gives each leg full contact with the ground instead of resting on a corner.
| Item | Qty |
|---|---|
| Construction lumber, 2x4, 8 ft | 5 each |
| Deck screws, 3" | 60 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 |
|---|---|---|
| I-beam spine boards2x4Two per sawhorse, sandwiched to form the I-beam. Build one horse's spine 2in longer than the other's so the pair nests. | 4 | 1 1/2" × 3 1/2" × 30" |
| Legs2x4Four per sawhorse. An optional 20-degree bevel on the feet improves stability on hard floors. | 8 | 1 1/2" × 3 1/2" × 30" |
| Leg caps2x4 | 2 | 1 1/2" × 3 1/2" × 30" |
Buy 5 boards at 8 ft.
5 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 →
Cut fourteen 30in lengths of 2x4 — enough for two I-beam spines, their caps, and four legs each.
Sandwich two spine boards together with a cap to form each I-beam. Build one spine 2in longer than the other — this is the one number that makes the pair stack.
Attach four angled legs to each I-beam spine. On the longer spine, set the legs close to the ends; on the shorter spine, set them 1in in from the ends — this offset is what lets the shorter horse nest inside the longer one.
Cut an optional 20-degree bevel on the bottom of each leg for full ground contact on a hard shop floor.
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