How to Build Sawhorses with Scrap Lumber
Ask This Old House carpenter Nathan Gilbert demonstrates how to build sawhorses using leftover materials from the job site
- Measure and mark scrap lumber to cut to length. To keep it easy, pick one measurement and cut all the lumber the same dimensions.
- Cut the scrap lumber to length using the miter saw.
- Screw a board perpendicular across two other boards with the drill driver to make the bottom piece of one of the legs. Do the same for the top part of the legs. Keep the top board flush with the top of the legs.
- Repeat this process for the other set of legs.
- Screw the hinges to the top board of the legs. Keep the hinge part below the top by about 1/8” so that it won’t interfere with anything you work on while using the sawhorse. To keep the measurement consistent, you can use a combination square and drag a pencil across it.
- Screw the hinges to the other set of legs using the same method.
- Drill a small hole in the center of the bottom braces of both of the legs.
- Tie the 550 cord through both of the legs to prevent the legs from bottoming out.
The materials Nathan used to build the sawhorses can be pulled from leftover materials from the job site or found at home centers. The tools he used to build them, including the drill driver, chop saw, speed square, and measuring tape, can all be found at home centers.
Nathan also used 550 cord to tie the legs together, which can be found at any military surplus store.
Expert assistance with this project was provided by Nathan Gilbert Carpentry.