If you want to learn more about how to build wooden sawhorses, you have to take a close look over the free plans in the article. If you want to have an easy workbench in any location without much effort or without investing a significant amount, you have the easy option: a couple of sawhorse and a tabletop made from 3/4″ plywood. In this article, you can see easy sawhorse plans made from 2×4 lumber. Moreover, my sawhorses are stackable so you can save space in your workshop.

If you want to get the job done in a professional manner, we recommend you to plan everything with attention, as to prevent costly mistakes and to build a professional garden bench. Invest in high quality materials, such as cedar, pine or redwood, as the bench will be exposed to all kinds of weather. Apply a few coats of paint over the components, to enhance their appearance and to protect them from bad weather.

Wooden Sawhorse Plans

Building a sturdy sawhorse

Materials

• A – 2 pieces of 2×4 lumber – 36″ long, 1 piece – 34″ long BEAM
• B – 4 pieces of 2×4 lumber – 28″ long LEGS

• 3 pieces of 2×4 lumber – 8′
• 100 pieces of 2 1/2″ screws
• wood glue, stain/paint

Tools

• Hammer, Tape measure, Carpentry square
• Miter saw, Drill machinery, Screwdriver, Sander, Router
• Safety Gloves, Safety Glasses, Respiratory Mask

Time

• One day

How to build stackable I-beam sawhorses

Assembling the I beams

The first step of the project is to build the I beam for the sawhorses. Cut the components from 2×4 lumber. Center the middle beam to top and bottom slats. Drill pilot holes and insert 2 1/2″ screws. Add glue to the joints and remove the excess with a damp cloth.

Attaching the legs

The next step of the project is to attach the 2×4 legs to the I beam. Align the edges with attention, drill pilot holes and insert 2 1/2″ screws to create super rigid joints. You need to insert at least 4 screws for a professional result.

Wooden sawhorse plans

You can easily adjust the size of the legs and therefore the height of the sawhorses. If you want to create a basic table, you need two sawhorses and a piece of plywood. In this manner, you can have a simple workbench in any location. If you like to work outside, you don’t need to invest in expensive portable tables, if you build a couple of these sawhorses.

Stackable sawhorse plans

We recommend you to check if the components are locked into place properly and structure is rigid enough for your garden. Make sure there are no protruding screws or sharp edges. If you are tight with the space in your workshop, I have a good news: these sawhorses are stackable.

PRO TIP: Apply several coats of paint or stain over the components, in order to protect them from decay. Check out the rest of the project to learn more about building garden projects.

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