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Among the most useful tools to have in your garage or workshop are sawhorses for supporting long planks of lumber, setting up a saw outdoors, or even laying out painted materials in a safe location until they dry. Learning how to build a sawhorse doesn’t need to be difficult when there are several innovative sawhorse plans available online.
Using simple sawhorse plans, almost anyone with basic woodworking skills can learn how to make sawhorses for their workshop. If you don’t have a lot of space, then consider working with folding sawhorse plans, or go with a set of heavy-duty sawhorse plans for a more robust build. Peruse the following downloadable sawhorse plans to find your next weekend DIY project.
1. Bob Vila’s Downloadable Sawhorse Plans
These exclusive folding sawhorse plans feature study half-lap joints—a useful construction technique for a wide variety of woodworking projects—as well as a convenient storage shelf and an easily replaceable sacrificial top. You can make a set for less than $100 in materials using the step-by-step photos, detailed cut list, and easy-to-follow illustrations included in the digital, printable plans.
2. Inexpensive Sawhorse Plans
These quick and easy sawhorse plans have a short material list to help keep the cost of the project affordable. The design of the sawhorses is relatively straightforward, and instructions for making detachable legs are included. When the legs are removed, they can be fastened to the sides of the sawhorse, allowing an entire sawhorse to fold up and hang neatly on the wall when not in use.
3. Beginner Sawhorse Plans
The instructions for these basic sawhorses from Etsy seller Horizon Design Studios is easy to follow, making it possible for new DIYers and beginner woodworkers to measure, cut, and piece them together. When the sawhorses are constructed, they cannot be folded up, but their rigid structure is excellent for supporting heavy items. Additionally, each sawhorse is built with a shelf that can be used for storage.
Get the Horizon Design Studios Sawhorse Plans on Etsy for $6.25
4. Knock-Down Plywood Sawhorse Plans
Experienced woodworkers and handy DIYers will appreciate the innovative design of these knock-down plywood sawhorse plans. The plans yield two relatively lightweight sawhorses using just one sheet of plywood. These sawhorses also have notches on top where long 2x4s can be installed to create the base for a worktable. Just add another sheet of plywood on top and you’ll be ready to work. It should be mentioned, however, that these plans are not step-by-step instructions, so they may not be the best option for beginners.
Get the Whitt’s Workshop Knock-Down Plywood Sawhorse Plans on Etsy for $6.95
5. Heavy-Duty Sawhorse Plans
Equip your workshop with this pair of thick, heavy-duty sawhorses that are durable enough to be referred to as “Sawstallions” by Etsy merchant Small Workshop Guy. Matchfit dovetail grooves extend along the top and sides of each sawhorse, making it easier for users to secure material to the sawhorse and preventing shifting while working. The sawhorse plans include a basic layout, cut list, and multiple instructional videos that demonstrate how to make specific cuts or build specific parts of the sawhorse.
Get the Small Workshop Guy Heavy-Duty Sawstallion Sawhorse Plans on Etsy for $19
6. Stackable Sawhorse Plans
Tackle large projects with these plans for six plywood sawhorses. And not to worry about storage space— all six sawhorses can be stacked on top of each other. When they are stacked, the entire set only takes up the floor space of a single sawhorse, making this design ideal for smaller workshops and garages. These plans are also effective for crafting inexpensive, lightweight sawhorses that can be loaded into a truck and carried to and from a construction site without much difficulty.
Get the Lakeland Wood Crafting Stackable Sawhorse Plans on Etsy for $5.55
7. Dual-Vice Sawhorse Plans
Standard sawhorses are typically made to support weight that is placed directly on top of them, but the plans for this dual-vice sawhorse will allow you to create a tough, durable product that can double as a narrow workbench. It has a relatively compact size, so it’s great for smaller workshops, but the real benefit of this design are the two vices built into the sawhorse. Users can secure wood, metal, or any other material by clamping it tightly in one of the vices so that it cannot shift while they work. Not only does this improve the outcome of cuts, but it also makes for a safer work environment.
Get The Joy of Wood Dual-Vice “Sawhorse on Steriods” Plans on Etsy for $34.18
8. 2-in-1 Workbench and Sawhorse Plans
It’s important to make effective use of the space that you have, especially if your workshop or garage is limited in size. With this in mind, you can create a sturdy sawhorse that can also function as a workbench by simply adding or removing the tabletop. Instead of using nails and screws, these interesting sawhorse plans use wooden dowels to secure the sawhorse pieces together. Dowel joinery is notably stronger than screw joinery, ensuring that this 2-in-1 workbench and sawhorse will last for years to come.
Get the Mikomi Atelier 2-in-1 Workbench and Sawhorse Plans at Etsy for $7.90
9. Sawbuck Plans
A typical sawhorse has a flat top designed to support pieces of lumber, but when you need to cut or saw through a log, it’s better to rely on a sawbuck. Sawbucks have a wedge-shaped opening that holds the log in place and prevents it from rolling. The plans for this sawbuck are very easy to follow, and the steps are simple to understand, even for beginners. Once completed, you will have a sturdy sawbuck assembly with six legs for superior support, and it can be folded up for storage when not in use.
Get the Firewood for Life Sawbuck Assembly Plans on Etsy for $4.95
The prices listed here are accurate as of publication on July 31, 2024.