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These sawhorses are extremely strong and easy to make.  After reviewing a number of sawhorse plans online I was disappointed with how complex most of the plans were.  These are quick and cheap to build.  They can carry hundreds of pounds and do not wobble. 

TOOLS:
Table Saw
Mitre Saw

Any of these tools can be used to notch the 2x4:
Hand saw, reciprocating saw, hammer and chisel, etc. 

MATERIALS (for two sawhorses):
One 8'  2X6
Four 8' 2X4s (three full 2x4s and some scraps over 10 inches will do)

Step 1: Instructions (Part One-Makin' the pieces)

Create the components in the image.  Use a 17 degree angle on the mitre saw and the table saw for all the angle cuts. 

To create the top piece (top left of pic):
Set your table saw to a 17 degree angle and run the 2X6 through to make a trapezoid.  The base of the trapezoid should measure 
5 1/2".  Cut this piece in half to make the two tops to your sawhorses.

To create the trapezoidal support piece(top right of pic):
Make sure your mitre box is set to a 17 degree angle.
Cut four trapezoidal pieces out of 2x4 such that they have a 10" base.  There should be four in total--two for each sawhorse.

To create the legs (lower portion of picture):
Make sure your mitre box is set to a 17 degree angle.

1- Cut Legs to length
Cut eight 30 1/2" long pieces out of 2x4s.  These should be parallelograms in profile and will form the 4 legs of each sawhorse. 

2- Notch Legs
On four of the legs notch the upper right piece out of the 2x4.  Measure down 5" from the top of the leg and notch out a 1" thick piece of the 2x4.  Notching deeper will compromise the horizontal wobble strength of the sawhorse.  I notched these by setting my mitre box depth and making multiple 17 degree slices an inch deep in the top 5" of the legs--I removed the remaining chunks of wood on the table saw and did the bottom portion with a hammer and chisel.  You may want to use a hand saw or reciprocating saw if you prefer. 
Repeat this process with the four other legs, except notch out the upper left portion of these. 


<p>you should just do &quot;i&quot; beam saw horses there much easier to make and are very durable,</p>
<p>Simple change, turn the cross beam 90&deg; and notch the brace. Your version is probably the one I'll make.</p>
<p>For the love of Odin, this project took me way too long and caused me a lot of frustration. I think about 98% of that was due to my astounding inability to follow directions and 2% due to the design. After making 17 errors 34 different ways, I salvaged the project by scoring 2x4 craps to brace the legs from the inside instead of making the 1&quot;x5&quot; 17 degree notches on each leg (using 3-4 different tools) that nearly lead to my commitment to a sanitarium. This is where I think the design is lovely, but unnecessarily over-complicated. The hatchet job mod that I made with the 2x4 brace actually works just fine. The sawhorses are strong and stable. I think the original design turns what is usually a purely utilitarian item into cool furniture. There are wealthy hipsters in Portland, Oregan who would pay $500 a piece for these and use them as a dining room table to show that they're down with the workingman. </p><p>I'm an intermediate DIY'er, so my skills are nowhere near those of the designer (and probably most of you). That should be a caution to those who may attempt this in the future--there is a lot of room for error if you're still learning some of the fundamentals on the job. </p><p>In the end, given what I'll use them for, they weren't worth the mental effort. Mostly that's due to my mediocrity, but can somewhat be attributed to a sawhorse design that is a little too cool for school.</p>
They went very well. About two hours total build time. <br>One problem I had was with the legs being mounted to the end of the horse, the screws split the 2x6 wood = so I moved the legs in about four inches. <br>Also one sat very sturdy on the floor and the other wobbled a little. Not sure why its legs were slightly uneven. <br>Over all I highly recommend these for some one about 5' 9&quot; in height. I'm over 6' tall and if building them again would add 6&quot; to the legs.
I will be trying this build out. I am always looking for good stacking and easy storing horses as well as sturdy and lightweight.
Please let me know how the build goes. For some old rotting <br>ones of these sawhorses I tacked on a two feet wide sheet of quarter ply on one side to sturdy them up.

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