Parts per sawhorse:
- 246 inches of 2x4 lumber, which is approximately 2.56 eight foot boards, so buy three boards. I bought Irving premium SPF at Home Depot. Fewer knots, doesn't smell, cheap.
- 24 deck screws of length 3". I bought Deckmate #9 x 3" screws at Home Depot.
- 8 deck screws of length 2". I bought Deckmate #8 x 2" screws at Home Depot.
- $12 for lumber and screws
- Compound mitre saw or your favorite way to make 15 degree cross cuts.
- Cordless impact driver or a drill and lots of patience with a screwdriver.
- Speed square
- Tape measure
- The first thing to measure and cut are the three pieces that form the I-beam. Measure 32", scribe, cross cut at 90°. Use this board as a template to mark the other two you need.
- Assemble the three 32" boards in to an I-beam as you see in the picture. This is simple. There should be roughly 1" on either side of the center board. Use the 2" deck screws to attach the top and bottom boards to the center. I put 3 screws across the top and 5 screws across the bottom underside, all more or less evenly spaced.
- Now measure and cut the legs. Legs are 29.5" long. The foot is a 15° cut as you can see in the picture. Make sure you measure the 29.5" on the longest side of the board. Cut four legs all the same way. You can also go ahead and cut four more for the second sawhorse now too.
- Attach each leg by pushing the 90° end up in to the I-beam corner as you see in the picture. Use four 3" deck screws to attach each leg. Be sure the angle cut foot is going in the correct direction before you attach each leg.
- Measure and cut the braces. These are 16" long with a 15° cut on each end. It's a trapezoid. Measure the 16" across the longest side of this trapezoid.
- Attach the leg braces as shown in the picture. Attach them to the OUTSIDE of the sawhorse legs. Use four 3" deck screws for each brace.
It's the same as the steps for the first sawhorse with the following changes:
- Make the I-beam 31.5" long (or 31....just shorter than 32).
- Attach the leg braces on the INSIDE of the sawhorse legs.
I wrote all this from memory, plus what I had jotted down on an index card. I may have left out a step. If you do not use an impact drive to run the screws in, you'll need to predrill and take your time.