This step by step project is about stackable sawhorse plans. I have designed this sawhorse with four legs, so you can use it on the job site or in the shop. This design is super durable and sturdy, so you can use it in the harshest conditions you can imagine. Moreover, the sawhorses are stackable, which means they occupy a small space. See more workshop plans HERE.
There are many designs and plans you could choose from, so you should take a look on more projects before starting the actual project. Nevertheless, if you are looking for a simple but sturdy design, this project might be the solution to your needs. Moreover, you could build all the components from 2×4 lumber, as to save both time and money. Make sure you check all the dimensions before making the cuts, otherwise the components might not fit together easily.
Made from this plan
Building stackable I-beam Sawhorses
- A – 4 pieces of 2×4 lumber – 28” long LEGS
- B – 3 piece of 2×4 lumber – 36” long BEAM
- C – 2 pieces of 1/2″ plywood – 6 1/2″x7 1/4″ long GUSSET
- Safety gloves, glasses
- Miter saw, jigsaw
- Chalk line, tape measure, spirit level, carpentry pencil
- Drill machinery and drill bits
- Pre-drill holes in the wooden components, before driving in the screws
- Use a good miter saw to make the angle cuts
- 1 hours
Stackable Sawhorse Plans
The first step of the project is to build the I-beam for the sawhorse. Center the bottom and the top slats to the middle support. Drill pilot holes through the bottom and top beams and insert 2 1/2″ screws into the middle support. Leave no gaps between the components and add glue to reinforce the bond of the joints.
Attach the legs to the I-beam, as shown in the plans. Align the edges flush, drill pilot holes and insert 2 1/2″ screws into the I-beams. Insert at least four 2 1/2″ screws through each leg into the I beam.
Use 1/2″ plywood for the gussets. Cut the gussets at the right dimensions and then attach them to the sawhorses. Align the edges flush, drill pilot holes and insert 1 5/8″ screws into the I-beams.
Smooth the edges with sandpaper and then make sure all the joints are sturdy.
Last but not least, you have to take care of the finishing touches. Therefore, you have to make sure all the screws are inserted properly and the whole structure is rigid. This design is ideal if you need more items, as you can stack them easily. In this manner, you can save a lot of space when stacking them.
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