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Stacking Sawhorses. You just need seven 2×4’s.
There are about one million different ways to make a sawhorse. I’ve designed and built about four types myself! But each time I build a pair and start using them, I discover things that need improvement.
Here’s why I like this design: it’s simple to build, but elegant. It’s sturdy, but fairly lightweight. The only lumber needed to build the pair are seven 2×4’s. And best of all, they stack easily.
A single sawhorse provides support for cutting boards. You can clamp the work piece to the top for even more support.
For a bigger work surface, drop a plywood board across two sawhorses.
Sawhorses have also become very popular in office and live/work spaces as cool inexpensive makeshift desks. In this case, I suggest building the stacking sawhorses and take the time to sand them down nice and smooth and either paint, stain, or finish them. A double thickness of ¾” plywood will be perfect for a desktop and I would screw it onto the sawhorses.
Building the stacking sawhorses
First, cut out all eight legs. Four will have 22.5° bevels on each end, and four will have 22.5° bevels on one end and 45° bevels on the opposite ends.
Arrange the legs so that one 45° bevel meets up with the face side on the other board. Make sure all the angles are facing the correct way.
Use glue and 2-1/2″ screws to connect the legs.
Align the legs by setting the cross braces on the ground and squaring up the top piece.
Screw the top and cross braces in place.
With the sawhorse tipped on its side, line up a board, draw a line where it meets with the front braces, and cut it out.
Screw these end braces into place, driving the screws into the legs.