Here’s a classic sawhorse that’ll take a ton of punishment with nary a wobble. The key is a boxlike construction where the legs join with the top board. For each one you make, you need:
- 1 42-in. long 2×6 for the top board
- 4 28-in. long 1×8 boards for the legs
- 4 8-3/4 in. x 7-in. x 3/4-in. thick boards for the gussets
- 2-in. drywall screws
Cut the gussets with 14-degree angled sides. Cut leg notches on the top board 6 in. from the ends and with 14-degree angled sides so the legs will cant outward when screwed on. Cut 14-degree angles on both ends of the legs with your circular saw’s table set at 14 degrees. Cut the taper along the inside edge of the legs, and loosely screw the legs in the notches. Now, screw and glue the gussets to the edges of the legs. Because you haven’t tightened the legs in the notches, they’re easy to line up with the gussets. After attaching the gussets, tighten the screws that hold the legs to the top board, and you’re done.
Thanks to reader Ernie Brown for this thoroughbred tip.