This sawhorse design was created by Josh Wright from the Josh Wright Woodworking channel, and it’s an excellent addition to any workshop. With just a single 2×6, you can create sturdy sawhorses perfect for your DIY needs.
Materials List:
- 1 – 2×6 (construction grade)
- Wood glue
- Polyurethane finish
Tools Needed:
- Table saw
- Miter gauge
- Drill
- Measuring tape
- Clamp
Step 1: Cut the Legs
Start by cutting a 30-inch section from the 2×6. From this section, cut two strips that are 2.5 inches wide and re-saw those strips in half to create four legs.
Step 2: Angle the Legs
Next, set your table saw to 15 degrees and your miter gauge to 10 degrees. Cut angles on both ends of each leg. After that, cut a notch in each leg to hold the leg supports, which should be 3/4 inch deep and 3 inches wide, starting 4 inches from the bottom.
Step 3: Prepare the Top Surface
Cut another 30-inch section from the 2×6 and rip it into two 1.5-inch wide strips and one 2-inch wide strip. Then, cut the 1.5-inch strips in half at a 15-degree angle to create angled strips for the leg supports.
Step 4: Create the Shelf Strips
From the remaining section of the 2×6, cut a 3/8 inch strip and rip the remaining piece into a 3-inch wide and a 1.75-inch wide piece. Resaw them in half, giving you two of each piece.
Step 5: Assemble the Leg Supports
Use one of the 1.75-inch strips to create two 16-inch pieces for the vertical supports. Cut a tenon on the ends and drill five half-inch holes spaced 2.5 inches apart.
Step 6: Make Dowel Pins
With the remaining strip, cut a 5-inch section to create two half-inch dowels. These dowels will be used to secure the pieces together.
Step 7: Glue Everything Together
Now, glue all the parts together, ensuring that the angled pieces are correctly positioned. The legs should be glued in 4.5 inches from each edge, and the shelf strips spaced about an inch apart.
Step 8: Finish the Project
Lastly, finish everything with a couple of coats of polyurethane for protection. Your sawhorse is now ready, and it can support up to 150 pounds easily!
With this simple guide, you can create your own sawhorse that is not only functional but also cost-effective.