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Short answer
To build a sawhorse, make a stiff top beam from 2x4s, attach four legs angled outward for stability, and brace the legs so they cannot rack. Build them in pairs, identical in height, so a board or a sheet of plywood sits flat across both.
A good pair of sawhorses is one of the most useful things you can build for a small shop: a cutting station, an assembly table and a temporary workbench in one.
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Pick the right height
Many woodworkers build sawhorses between about 24 and 30 inches tall. Lower horses are better for sawing and for working on big parts like doors and cabinets; taller ones double as a work table when you lay a sheet of plywood across them.
If you are not sure, match the height of an existing table or bench, so the horses can extend it for long boards.
Design 1: the quick 2×4 sawhorse
- Make the top beam from two 2x4s screwed together in a T — one flat on top, one on edge below it. The T shape makes the beam very stiff.
- Cut four legs from 2x4s. Angle them outward both toward the ends and toward the sides, following your plan’s angles, so the horse has a wide stance.
- Screw the legs to the beam, pre-drilling to avoid splitting.
- Add a plywood gusset or a stretcher between each pair of legs so they cannot spread or rack.
- Screw a 1×4 cap on top as a sacrificial surface you can saw into and replace.
Design 2: folding or stacking horses
Folding sawhorses pair two leg frames with hinges at the top and a strap or chain to set the spread; they fold flat and hang on a wall. Stacking designs nest one on top of another, which saves floor space in a garage shop.
Both are worth the extra work in a small shop, where every square foot counts — the ideas in how to lay out a small garage workshop apply to tool storage like this too.
Materials for a pair
| Part | Material |
|---|---|
| Top beams | 2×4 lumber, two pieces per horse |
| Legs | 2×4 lumber, four per horse |
| Braces or gussets | 3/4-inch plywood offcuts or 1×4 |
| Sacrificial caps | 1×4, one per horse |
| Fasteners | 2 1/2- and 3-inch construction screws, wood glue |
Details that keep them steady
- Build both horses at once, cutting matching parts together, so they come out the same height.
- Check for rocking on a flat floor and trim the long leg rather than shimming.
- Add a shelf across the lower braces to hold a drill, clamps and a tape measure.
- Glue as well as screw the joints; glue keeps them tight after years of use.
- Never stand on a sawhorse; it is built for work, not as a ladder.
Turn them into a workbench
Lay a sheet of 3/4-inch plywood across two horses and you have a full-size assembly table that stores in minutes. It is a practical first step before building a permanent bench, as described in workbench plans for beginners.
Use them as a cutting station too: support the board on both sides of the cut, so the offcut does not fall and pinch the blade.
More shop projects from one library
TedsWoodworking lists sawhorses among the plan types in its Workshop & Tools category, which holds more than 1,850 plans. Every plan in the 16,000-plan library includes step-by-step instructions, exact cut lists, complete materials lists and multi-angle schematics with exploded views of every joint.
A look inside TedsWoodworking
FAQ
How tall should a sawhorse be?
Usually between 24 and 30 inches. Lower is better for sawing and large parts; taller works better as a table.
What wood is best for sawhorses?
Straight, dry 2×4 construction lumber is ideal, with plywood for gussets and braces.
How much weight can a wooden sawhorse hold?
It depends on the design and lumber. A well-braced 2×4 pair handles typical shop work easily; follow your plan and never stand on them.
Are folding sawhorses as strong as fixed ones?
A well-built folding pair is strong enough for most work, and it stores flat in a small space.
Next step
Buy six straight 2x4s this weekend and build both horses side by side, cutting matching parts together.
Based on standard shop practice for 2×4 and folding sawhorses. Product details for TedsWoodworking are from the vendor’s published offer page as of September 29, 2026.
