A folding sawhorse is an indispensable tool for anyone that works around the house. With a few tools and materials, you can make your own sawhorse for a very small price.
Step 1 - Bevel the Top Edge of the Legs
Using your circular saw, bevel the top edge of all of the legs at a 15 degree angle. An easy way to do this is to lay the wood on a flat surface and mark the 15 degree angle with a straight edge. Draw a line along the straight edge with a pencil and use the line as a guide when using the circular saw.
Step 2 - Attach Plywood to 2 Legs
Lay the 2 legs out on your work surface with the beveled edge facing down. The beveled edge should be at the top of the work surface. Line up the edges of the plywood with the edges of the legs. Use your drill to screw the plywood top to the legs. You should use 2 screws on each end of the plywood.
Step 3 - Attach Opposite Legs
Now that you have one half of the sawhorse constructed, turn it on its opposite side. The plywood board should be flat on the work surface. The beveled edge of the legs should be facing you at the top of the work surface.
One inch down on the inside of the legs, drill a pilot hole measuring 1/4 inch in diameter. Drive the 3 1/2 inch nail into the pilot hole with a hammer. You want to hammer the nail into the pilot hole until it is sticking out only 1 inch. Use your reciprocating saw to remove the head of the nail.
Drill a 1 inch pilot hole inch down on the inside of the opposite legs. Lay the opposite legs next to the legs that are already attached. The beveled edge should be in the opposite position. Push the opposite legs onto the 1 inch length of nail that is protruding from the outside legs.
Step 4 - Attach Second Plywood Board
Leave the sawhorse in its current position and place the second plywood board on top. Line the edges up with the edges of the outside legs. Though the edges are lined up with the edges of the outside leg, you will need to screw into the inside legs that you just attached. If you screw into the outside legs the sawhorse won’t open.
Use the drill to drive screws through the plywood into the inside legs. Use 2 screws on each side of the plywood board.
Step 5 - Create Rope Stop
Leave the sawhorse in its current position to add the rope stop. Drill a hole through both pieces of plywood. Knot one end of the rope. Feed the other end through the hole and knot it. When the sawhorse is open, it will be stopped in place by the rope stop.