Instructables

Simple Easy Folding Sawhorses

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Sawhorses are indispensable for a normal household or a shop. You can use them for painting, work piece support, work bench support with a piece of plywood or door, and with a little imagination, they can be used in many other different ways like magic. The folding sawhorses are particularly valuable, as they can be stored with very minimum space, carried in your vehicle, and set up quickly when you need them.

 

There are many ways to make folding sawhorses, and it’s not the intention to claim that this is the best way, it's just my way of doing it. If somehow there’s a design details that has been seeing somewhere else, that means either the design was inspired by the other fellow designer's creative mind, which is really appreciated, or all good engineers follow the same physics & design principle - simple, functional, most efficient in strength and maximize material usage. I am sure there are some rooms for improvement for this project, please comment with your idea, and we’ll make it better –  will try to make another pair in the near future if necessary.

 

One more thing to take consideration, the sawhorses were not tested to see how much weight that they can hold up, except I only jumped up and down on one of them with my 175lb body, so they can probably hold at least 200lb each without a problem.

 
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allen1 year ago
About a million years ago my dad knocked together a couple of almost-identical saw horses out of some reclaimed lumber and door hinges. There were a couple of differences between my dad's design and yours.

First, the hinges were *below* the top of the saw horse. That causes the top edge of the saw horse to pinch together. But my dad cagely planed away a bit of the top, inside edge of each top piece to provide some clearance.

That gave him both a straight top to the saw horses - no hinges standing above the line of the horses - and made it tougher to hit the hinges when sawing.

Also, rather then a chain and eye bolts he drilled a small hole in each leg and a knotted bit of rope.

Dang, I'd forgotten about those horses and they were pretty sweet. Cheap, strong, storable, easy to handle, easy to make.
I love the idea of the knotted rope, as it can be used to tie the legs together when folded. Dad's are great... thanks
Jzbowmannz (author)  allen1 year ago
Thanks for the comment, Allen.
As I said in step2 and showed in the second picture, I was planning on put a couple of piece of boards on one side of the folding piece along the beam, it acts as a sacrificial piece, as well as to gain more height for the sawhorse, and the edge of that board will also be higher than the hinges.
To do what your dad did involves more woodworking and machining processes, the gate hinges (being the tapered shape) will also be difficult to aligned/attached in order to keep them at consistent locations and work properly. It will need some kind of spacer to do that. Appreciated your input, I'll try to do that on my second pair for the improvement.
rexit1 year ago
I used to make these in the wood shop I worked at but I used all 3/4" material with no angles......I made a T out of 3/4" and 1/4" to drop down in the slot...Your use of angles is a great improvement...
BigMrTree1 year ago
Amazing!! I'm going to build some of these pronto!!
ProfMuggs1 year ago
Nice job! I especially like your detailed drawings.
Jzbowmannz (author)  ProfMuggs1 year ago
Thanks. They were a little rough, but I tried to show my thought process with notes and some other lines still on there.
Fantastic! This is a genius design. :D
Jzbowmannz (author)  jessyratfink1 year ago
Thanks for the encouragement.