Handy Dandy Stackable Sawhorses

 DIY STACKABLE SAWHORSES

 I would just like to start off by saying thank you for visiting my blog all about woodworking! I will be posting tutorials, projects I'm currently working on, tips & tricks and all sorts of other things!

First I would like to start with my first project which in essence will lead to many more completed projects in the future. As far as I'm concerned EVERY work shop needs these...sawhorses!

This is sortof a DYI tutorial on how to make them as well as just showing my project. Here we go:

Exactly why I'm building these. Cutting wood out of a trunk in winter sucks lol

I used nine 8 foot 2x4's. -Take 5 of the 2x4's and cut them at 47". This should leave you with 5 47" pieces and 5 49" pieces (assuming your 8footers are very close to 96") -now you want to take 4 of your 8 footers and cut 8 32" pieces(you should be able to get 3 per piece but mine were about 1/8th" under 96" so only got 2 exact 32" per board with decent sized scraps)

Next, we'll assemble the I-Beam as shown above, starting with the three 49-inch boards. On the ends of two of the boards, mark a centerline across the short axis of each end. When those four marks are in place, mark a centerline down the long axis at each end of the third board, as shown by the center board in the diagram. Now, using the screws, attach the top board to the center board. Place a few screws down the length of the top board and into the center board, making certain to keep the centerlines on both ends aligned. When the top board is attached to the center board, flip the assembly over and attach the bottom board in the same manner. When complete, you should have a long I-Beam. *repeat same process for the 47" boards to make that Ibeam*

we'll work with the 49-inch assembly. Lay the I-Beam on it's side. Grab one of the legs and place the end just under the lip of the top board of the I-Beam. Making sure that the side of the board is flush with the end if the I-Beam, attach the leg to the I-Beam using two screws into the center board and two into the bottom board of the I-beam. Once one leg is done, repeat with the other leg on the same side of the I-Beam. Then, flip the entire assembly over and attach the legs to the other side of the I-Beam. 

When all four legs are attached, stand the assembly on it's legs and check for any wobble. The legs can be spread out slightly by hand if necessary for all legs to be on the floor evenly. Once the 49-inch I-Beam assembly is completed, perform the same steps on the 47-inch I-Beam. Once both units are standing on their own four feet, its time to stabilize the legs. Once again, we'll begin with the 49-inch assembly. Cut two 49-inch pieces from two 2x4's. (Save the cutoffs, as they'll be used in another step.) Using the tape measure, place a mark 10 inches up each of the four legs on their outsides. Square the mark using the Layout Square. Attach one of the two cut pieces to the two legs on one side of the assembly, aligning them just on top of the square marks and with the ends of the boards flush with the sides of the legs. Repeat on the other side. Two screws at each connection will suffice. 

Now that the 49-inch sawhorse assembly is completed, we'll turn our attention to the 47-inch assembly. Because the 49-inch assembly will stack on top of the 47-inch unit, we'll need to construct this one a bit differently. Notice, in the image above, that the side stringers for this unit are on the inside of the legs, as opposed to the outside on the other sawhorse. Otherwise, this step is the same. Make a mark 10-inches up each of the four legs, on the inside this time. Square the mark using the Layout Square. Trim the two cutoffs you retained from the last side stringers to 47-inches in length. Attach them as shown in the image, paying attention to stay on the top of the pencil lines and with the ends of the boards flush with the sides of the legs.

To finish the second sawhorse, we'll use a similar technique to the one we used on the first sawhorse. Notice the position of the end stringers in the image above. Place a piece of 2x4 on top of both side stringers overlapping the legs at the ends. Use the legs to scribe cut marks on the end stringers. Cut the two boards to the lines, and attach them to the legs with 2 screws on each attachment point.