Building a sawhorse might seem like a straightforward task, but it’s a timeless skill that has been used by seasoned carpenters to test apprentices for generations. Known by some as trestles or trestle benches, sawhorses are more than just basic tools—they are versatile, sturdy, and essential in any woodworker’s arsenal.
In this article, we’ll explore the fascinating history of sawhorses, their practical applications, and a step-by-step guide to crafting one yourself.
The History and Evolution of Sawhorses
Sawhorses have been a staple in woodworking for centuries. In the past, they were often used as scaffolding or work platforms when spanned by planks. Old-timers referred to them as trestle benches, and apprentices were judged on their ability to construct sturdy and functional versions of these tools.
In earlier times, when handsaws were the primary cutting tool, sawhorses were typically built at knee height (about 2 feet). This height allowed carpenters to stabilize the wood with one knee while sawing, providing optimal control. While modern power tools have changed some practices, the traditional 2-foot height remains practical for many tasks.
Why Every Workshop Needs a Sawhorse
Sawhorses are indispensable for any construction or woodworking project. Their versatility and practicality make them a must-have for tasks ranging from simple cuts to complex scaffolding. Here’s why:
- Work Platforms: Spanning two sawhorses with sturdy planks creates an elevated platform, perfect for working at height or as makeshift scaffolding.
- Work Tables: By adding a plywood panel on top, they double as temporary work tables.
- Custom Heights: Whether you need to reach high ceilings or work close to the ground, the height of sawhorses can be customized to suit the job.
- Portability: Lightweight designs allow them to be easily moved around the workspace.
Materials and Tools Needed to Build a Sawhorse
Before you start, gather these essential materials and tools:
Materials:
- 2×4, 2×6, or 4×4 wood for the crossbeam
- 1×12 board (optional for adding a shelf)
- Plywood scraps for gussets
- Wood glue
- 8d nails or screws
Tools:
- Handsaw or power saw
- Framing square
- Chisel
- Hammer or drill
- Sliding T-bevel
Step-By-Step Guide to Building a Sawhorse
1. Prepare the Crossbeam
Choose a straight, clear piece of wood for the crossbeam. A 2×6 cut to 42 inches is a good starting point for most projects. Ensure it’s free of knots or defects, as this is the structural backbone of the sawhorse.
2. Cut and Shape the Legs
To make the sawhorse stable, the legs should splay in two directions. Follow these steps:
- Measure and cut four legs to about 26 inches each for a 2-foot-high sawhorse.
- Use a framing square to set the angles. A 4-in-24 angle works well for stability.
- Cut compound angles on the tops and bottoms of the legs to ensure a snug fit into the crossbeam.
3. Create the Gains (Mortises)
The gains are the notches where the legs fit into the crossbeam. Here’s how to make them:
- Measure 4 inches from the end of the crossbeam and mark the outline of each gain.
- Use a saw to make parallel cuts within the marked area, then chip out the waste wood with a chisel.
- Clean up the edges for a precise fit.
4. Assemble the Sawhorse
- Apply glue to the gains and insert the legs.
- Secure the legs with 8d nails or screws. For added strength, use trapezoidal gussets cut from plywood to brace the legs. Attach these with glue and screws.
5. Add a Shelf (Optional)
If you need extra storage or added stability, include a shelf:
- Cut a 1×12 board to fit snugly between the legs.
- Attach the shelf with screws and reinforce the edges with 1×2 strips to prevent tools from rolling off.
6. Finishing Touches
- Sand down rough edges to prevent splinters.
- Optionally, cover the crossbeam with a piece of scrap plywood to absorb saw cuts. Avoid using nails to attach it; glue works best to prevent accidental blade damage.
Pro Tips for Long-Lasting Sawhorses
- Use Quality Wood: Opt for straight, knot-free wood for durability.
- Avoid Drywall Screws for Load-Bearing Parts: They are brittle and may snap under pressure.
- Store Properly: Stack sawhorses to save space, placing ones with shelves on the bottom.
Modern Uses for Sawhorses
While their design has remained relatively unchanged, the applications of sawhorses have evolved with time. Today, they are used not only in construction but also in crafting, painting, and even as temporary furniture. Their simplicity and utility continue to make them a valuable tool for professionals and hobbyists alike.
Conclusion
Crafting a sturdy sawhorse is more than a woodworking exercise—it’s a rite of passage that connects modern carpenters to their predecessors. By following the steps above, you’ll not only create a functional tool but also carry on a time-honored tradition. Whether you’re building scaffolding, assembling furniture, or tackling a DIY project, a reliable sawhorse will always be there to support your work—literally and figuratively.
So grab your tools, pick your wood, and build something that will stand the test of time. After all, a well-made sawhorse isn’t just a tool—it’s a testament to your craftsmanship!
