This sawhorse design is inspired by a design from Patrick McCombe, who built a pair for Fine Homebuilding.
I like my design, because it fits what I need it to do. Some commercial sawhorses are too tall for me, (I’m 5’2″ tall), others are annoyingly short. I wonder who or what they were made for.
Decide how tall you need your sawhorses, and how long. For those doubling as picnic table holders, I like my sawhorses 26-28 inches tall- about that of a dining table (with the door on it). For holding shorter boards to become a potting bench or drying rack, 32″ with the top board.
Stock lumber is used, so no planning is necessary. You could pick up scrap pieces at the DIY store for a song.
Here, I’ll describe the 27 inch tall saddle holder.
You will need:
- One 2-by-8 board, 48 inches long
- 1-by-4 pine wood
- ¾” plywood, 2-by-4 sheet if no scraps available
- Drill and bits
- Measuring tape and marker
- Table saw, miter saw or circular saw- all will work with this project
- One box #10 wood screws, 1 ½” long
One:
Cut your wood:
The 2-by-8 should be 48 inches long, with a bevel along each side of 17-degrees
Cut four pieces of 1-by-4, each 27 inches long with a 17-degree miter at one end
Cut two pieces of 1-by-4, each 40 inches long
Step Two:
On the top piece, measure and mark 4 inches in from each end. The legs will attach here. The bevel should widen from the top down so the legs spread from the top.
Pre-drill and screw the legs to the top, so the miter end sits flat on the floor.
Step Three:
Measure and mark 12″ up from the bottom of each leg. Attach the 40-inch long leg braces here.
Step Four:
Hold the scrap plywood on top of the legs just under the top of the sawhorse. Trace the gusset here. It should be at least six inches in height. Leftover 1-by-6 wood also works here. Attach with screws.
Step Five:
Your sawhorse should be sturdy and level. Cut the ends of the legs flush with the top of the sawhorse.
Sand, stain, paint or seal your sawhorse. If using for a saddle holder, a tray can be fashioned and attach across the leg braces to hold brushes and other items. Attach hooks for bridles, lead ropes, etc.
Step Six:
Enjoy your sawhorse. For a picnic, place a plain hollow-core door across both horses and cover with a table cloth. A 4-by-8 sheet of plywood works well, too.
Depending on the scrap wood you have in your workshop, this sawhorse can cost as little as the price of time and a few screws, or clearance wood at the DIY store.
Source: Patrick McCombe, “Building Sturdy Sawhorses,” Fine Homebuilding website, no date given
