Stackable 2x4 Sawhorses — board plan

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

Buy 5 boards at 8 ft.

1 1/2" × 3 1/2" — 2x4

5 boards · 17.6 board feet (includes 15% for knots and defects) · 89% of the boards you buy used

Board 1 · 4 5/8" left over
30"30"30"
1. I-beam spine boards — 30"
2. I-beam spine boards — 30"
3. I-beam spine boards — 30"
Board 2 · 4 5/8" left over
30"30"30"
1. I-beam spine boards — 30"
2. Legs — 30"
3. Legs — 30"
Board 3 · 4 5/8" left over
30"30"30"
1. Legs — 30"
2. Legs — 30"
3. Legs — 30"
Board 4 · 4 5/8" left over
30"30"30"
1. Legs — 30"
2. Legs — 30"
3. Legs — 30"
Board 5 · 34 3/4" left over
30"30"
1. Leg caps — 30"
2. Leg caps — 30"

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

Board 1 · 4 5/8" left over

Board 2 · 4 5/8" left over

Board 3 · 4 5/8" left over

Board 4 · 4 5/8" left over

Board 5 · 34 3/4" left over