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@JGD - Great sawhorse design improvement! I see what you're saying about notches for rigidity, taking that a step further, wondering if a 2x6 notched on top for 2x4 AND on bottom to drop "into" the plywood brackets would work w/o screws/bolts. Alternatively (or in addition to notching), maybe a long lag bolt could screw into the crosses from the underside of the brackets through a washer and a 1x3 (wide enough to catch the brackets, but removable for stacking). Would only go ~1" into a 2x6 crossbar to prevent errant saw cuts from hitting the lag bolt...and making sparks. ;-)
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