Welcome to my Sawhorse Furniture Instructable! I designed this DIY furniture series so that it didn't require any advanced carpentry skills and only a few tools. This build is easily scalable so it can be applied to a variety of furniture typologies. So far, I have designed and built a bench and a platform bed frame using this design language. (Dimensions: Width 18", Depth 12", Height 16")
Step 1: Gather Your Tools and Materials
For this build you will need the following items:
2) 2x4x96 Premium Whitewood Studs
1) 1lb box of 3" Construction Screws
1) Tape Measure
1) Marker or Pencil
2) Clamps (Throat Size > 6.5")
1) Drill Driver, bit holder & bits (Most construction screws come with bits)
Step 2: Cutting the Wood
This build requires crosscuts only. If you don't have a saw, most home improvement stores / lumber yards will provide this service for free or just few cents per cut. I got mine cut at the store, makes for ease of transporting via bicycle, also.
Step 3: Spacer (Recommended If Making Multiples)
I designed the spacer to help with the assembly of the I-beam. Follow me at www.instagram.com/liv_lab for details about the spacer.
Step 4: Constructing the I-beam (Clamping With Spacers)
The spacers do not need to be pretty, there function is to help to keep the wood properly aligned during assembly.
Step 5: Constructing the I-beam (Screwing the Pieces Together)
I recommend pre-drilling the holes for your screws if you do not have a powerful drill. The construction screws are self-tapping but they still will put a load on the drill.
Step 6: Attaching the Legs
Align the top of leg with the inside edge of the 2x4, (Tip: stack a few of the extra pieces of wood to help hold the leg at the right angle) drive the screw closest to the top first, then proceed to drive the lower.
Step 7: Attaching the Legs
Step 8: Constructing Table / Seat Surface
Place the 12" piece of wood (Stringer) in the opening at the end of I-beam, fasten with screws and repeat.
Step 9: Constructing the Table / Seat Surface
Fasten the two 18" pieces of wood to the stringers
Step 10: Construction Done!
Fill in the screw holes with some wood filler, and sand. Paint it or leave it unfinished for a rustic / industrial look.