Stackable Sawhorse Plans

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.

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

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Building stackable I-beam Sawhorses

Building stackable i beam sawhorse

Building stackable i beam sawhorse

Materials

  • 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

Tools

Tips

  • Pre-drill holes in the wooden components, before driving in the screws
  • Use a good miter saw to make the angle cuts

Time

  • 1 hours

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Stackable Sawhorse Plans

Building the I-beams

Building the I-beams

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.

Fitting the legs

Fitting the legs

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.

Fitting the plywood gussets

Fitting the plywood gussets

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.

Stackable Sawhorse Plans

Stackable Sawhorse Plans

Smooth the edges with sandpaper and then make sure all the joints are sturdy.

DIY Stackable Sawhorse Plans

DIY Stackable Sawhorse Plans

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.

Smart Tip: Fill the holes with a good filler, let it dry out and sand the wooden surfaces with 120-grit sandpaper. Vacuum the residues and apply several coats of protective paint.

 

 

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