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Stackable 2x4 Sawhorses

A pair of 2x4 sawhorses built with a sandwiched I-beam spine, sized so one nests inside the other for storage.

Cut list

Part	Qty	T × W × L	Material	✓
I-beam spine boards Two 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"	2x4	☐
Legs Four per sawhorse. An optional 20-degree bevel on the feet improves stability on hard floors.	8	1 1/2" × 3 1/2" × 30"	2x4	☐
Leg caps	2	1 1/2" × 3 1/2" × 30"	2x4	☐

Item	Qty	✓
Construction lumber, 2x4, 8 ft	5 each	☐
Deck screws, 3"	60 each	☐

Overall cost: $. Lumber varies by region, species, and season, so we give a band rather than a figure.

1. Cut all the pieces
Tools: Circular Saw, Tape Measure. Materials: Construction lumber, 2x4, 8 ft
Cut fourteen 30in lengths of 2x4 — enough for two I-beam spines, their caps, and four legs each.
2. Build the two I-beam spines
Tools: Combination Square, Drill / Driver. Materials: Construction lumber, 2x4, 8 ft, Deck screws, 3"
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.
3. Attach the legs
Tools: Drill / Driver. Materials: Construction lumber, 2x4, 8 ft, Deck screws, 3"
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.
4. Bevel the feet (optional)
Tools: Circular Saw
Cut an optional 20-degree bevel on the bottom of each leg for full ground contact on a hard shop floor.