Every workshop has or needs at least one set of sawhorses, and this heavy duty sawhorse is the one that will last for ages and take almost any beating you can give it. I remember my dad having a set of these out behind the garage from my earliest childhood memories, and they saw tons of use as I grew up.

Materials needed for one sawhorse:

• 1 – 2×4 @ 12′
• 2 – 2×4 @ 10′
• 2 1/2″ exterior grade wood screws

Building your own heavy duty sawhorse

The construction of this heavy duty sawhorse is straight-forward and about as easy as it gets. There are no angled cuts, and no hinges to install. Just basic straight cuts and driving screws.

1. Start by cutting your three 36″ pieces for the i-beam from a 10′ 2×4, then screw them together with the wood screws. Make certain to counter-sink the screws on the top of the i-beam at least 1/4″. You’ll want that clearance for your blade when cutting directly on these sawhorses.
2. Cut your legs from the 12′ 2×4. Use a framing square to ensure you are attaching them perpendicular to the i-beam. They should be inset 1 1/2″ from the ends of the i-beam. Use four wood screws for each leg.
3. Cut and attach the rails from the remaining 10′ 2×4. Use two wood screws at the end of each board.

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