Make a Free and Versatile Sawhorse

Most people don't give much thought to sawhorses until you need one or a pair. If you follow these simple, easy to follow directions, you'll quickly discover how handy they are to have around and how many different uses they have. This can be a fun project so, involve the family, create a useful household item and, most of all, enjoy.

The free, or nearly free part is totally optional. We use used wooden pallets for our sawhorse material, but you are welcome to substitute finished lumber if you desire a more dressy sawhorse. One pallet, typically 42" x 48" in dimension, made from 1"x4" slats nailed or stapled to 2"x4" runners, will provide material for one sawhorse. Since most uses of sawhorses require two, we suggest you first find two pallets in good condition, that has no missing slats and is not splintered or heavily weathered. Most businesses have stacks of unwanted pallets sitting behind their buildings, so a quick tour of your neighborhood shopping area will usually provide several sources. Be sure to obtain permission, which is usually readily granted, before hauling off your pallets.

Here is a list of tools you will need for this project:
A crowbar, wonder bar or nail puller.
A claw hammer.
A measuring tape.
A marking pencil.
A t-square, or speed square.
A saw_ either a hand saw, a skill saw, or better yet, a miter saw.
An electric drill.
A 1/8" wood drill bit.
A screw bit that fits the head of the screws you will use. (note: a magnetic bit holder will make driving the screws much easier, but is not essential)

The first step is to carefully dismantle the wooden pallets, taking care not to split any of the wood. Next, carefully remove all nails and staples from all wood pieces. This is important to prevent ruining a saw blade on an embedded nail or staple.

After all the pieces are cleaned and stacked, begin measuring all the pieces for cutting. Here is a list of the pieces required for one sawhorse:

From the 2"x4" pallet rails:
2 pieces, 12" long, cut square on each end.
2 pieces, 9" long, cut on a 22 degree angle at each end, so both ends taper in, like a pyramid. The top edge should be 73/4" and the bottom edge should be 9" long. (see closeup photo)

From the 1"x4" slats:
Measure 2 pieces 36" long. Two suggestions here. Pick the best two pieces, as these are used for the top edges of the sawhorse. Second, when measuring for all 1x4 pieces, mark your pieces in the middle of the slats, cutting off the ends, which have nail holes and are most likely to have damage.

Measure 4 pieces, 30" long for the legs. Here you have some flexibility, depending on the use of the sawhorses. If the sawhorses are strictly for woodworking use, you might prefer a "knee high" sawhorse, in which case the legs can be measured at 24". I prefer the 30" legs, which makes the sawhorses 32" high, perfect for use as a base for adding planks or an old hollow core door for garage sales and picnic tables, or even a quick and portable work bench. However, the choice is yours.

After all pieces are cut, assembly is the next step. You have the option of using either nails or screws. Nails are cheaper and might be more readily available. Screws are easier to use and provide a more secure product. My preference in this case is decking screws, either Phillips head or square head. In either case, it is highly recommended that all pieces are pre-drilled to prevent splitting the wood. Hold each piece securely in place, drill through the first piece so the drill bit penetrates into the second piece, then complete the drill hole in the second piece, using the small indentation made from the penetration as a guide.

Screws or nails recommended for one sawhorse are:
4-3" screws or nails for the 2x4 pieces.
32-11/2" screws or nails for the 1x4 pieces.

There is a specific order to the proper assembly of your sawhorse.
First, mark the center of the tapered 2x4 on the 2" edge. Then, mark the center of the 12" 2x4 on the 2" edge at one end. Line up the two center marks and make certain the 12" piece sits squarely on the tapered piece. (see closeup photo)

Holding the two 2x4 pieces securely in place, drill two holes from the bottom of the tapered 2x4 straight upward so the drill bit penetrates the end of the 12" piece. Then, complete the holes in the 12" piece at least 11/2" deep.
Secure the two sets of 2x4 pieces with the 3" screws or nails.

Next, fasten the two, 36" 1x4 slats to the assembled 2x4 frames so the top edge of the 1x4 slats are flush with the top edge of the vertical 12" 2x4 and flush with the end of the same 2x4. Use 2-11/2" screws or nails for each end of the 1x4 top piece. Repeat for the other side of the 12" 2x4 frame. (see second photo of sawhorse).

The next step is to fasten the four legs to the assembly. The top edge of each 1x4 leg should be flush against the bottom edge of the 1x4 top piece and squared against the tapered edge of the angled 2x4 piece. Use 2-11/2" screws or nails for securing the top end of each leg and two more 11/2" screws or nails to secure the middle of the leg into the tapered 2x4 piece.

When all the assembly is completed, you have several options available. If the sawhorses are for indoor workshop use, no finishing is required. However, if the sawhorses are stored outdoors and exposed to inclement weather, you might want to paint the sawhorses with a good, exterior primer and an exterior finish coat the color of your choice. If a more dressy look is preferred, such as for a picnic table base, you can sand the sawhorses for a more finished look before painting, or, as suggested earlier, substitute finished lumber for the pallet lumber. If buying finished lumber, one- 2"x4"x8' and two- 1"x4"x8' will make one sawhorse.

Sometimes you will find pallets constructed of very nice looking wood. I have found maple, oak, ash and, on occasion, some walnut or cherry wood in pallets. If you find good looking lumber in a pallet, this give you the option of sanding or planing the pieces and applying a clear varnish or polyurethane finish for a very dressy looking sawhorse. One hint, if you want to focus on nice wood, find an importer who has pallets, as most hardwoods will come from overseas.

Another alternative is to use pressure treated lumber and avoid the extra step of painting, yet having sawhorses that can be left outdoors. A simple table top can be easily assembled to the length and width of your choice by cutting 2x6 or 2x8 lumber to the same length and securing with 1x4 pieces 6 to 8 inches in from each end and in the middle, across the 2x6 pieces, drilling and screwing two. 11/2" screws into each 2x6, then flipping the assembled top so the 1x4 cross pieces are on the bottom.

Since projects like this are such low cost, allow your imagination to flow and you might find new, unique uses and creative methods of decorating your sawhorses. You might even be inspired to start a new cottage industry, selling decorated sawhorses at outdoor flea markets. Have fun with the project!