Over time I've needed a saw horse.  I have just one made from some plastic parts, four 2x4s, and a 2x6 top that is the same height as my Black&Decker WorkMate.  

I've watched many YouTube Video of makers making their own saw horse set, and seen all sorts of designs both commercially made and shop made.  There are A frame versions and T-post versions generally. Of the A frame versions all have a chain or shelf or some strategy to keep the legs from splitting apart when they stand up. 

I've come up with an A frame design that eliminates the need for a tension member between the legs. A short write up and photos of 1/4 scale models and a version that holds up my small jointer are here:  https://4dfurniture.blogspot.com/2022/04/a-simple-saw-horse-design.html.

I design it to be CNC cut from 18mm Baltic Birch plywood.  The top bar can be a 2x4 or any wood chunk 1.5" thick. 

 

4D

Nice design and I like the folding idea to conserve space. 
 

My saw horses often go outside for extended periods of time. Wonder if plywood would hold up in the weather. 

33 minutes ago, lew said:

My saw horses often go outside for extended periods of time. Wonder if plywood would hold up in the weather. 

The design could be made from marine plywood.  If I took Baltic Birch plywood out to play in the sun I'd coat it with varithane/spar urethane.

4D

There are a myriad of sawhorse plans out there from dead simple to complex.  I've seen something similar to this one in an article recently.

 

In 1977, I made my first (and only) sawhorses, still in use today, three states and five houses later.   I got the plan from Mother Earth News.   I bought a 8' 1x10 for legs and scrounged some 2x6 pieces from the scrap pile where they were building behind where I lived.   With a hand saw, chisel, and hammer, I got them together in the small basement of my apartment.   Legs were tapered (ripped the 1x10 at an angle) and flared in two directions.  I chiseled out where the legs attached to the top.  Used "spiral" nails.  And a couple of pieces of scrap 1/2" plywood for gussets.  Stackable.  Bob's your uncle.

 

Very similar to this one, but it just has the top beveled instead of a notch cut out

 

Edited April 15, 20224 yr by kmealy

19 minutes ago, kmealy said:

There are a myriad of sawhorse plans out there from dead simple to complex.  I've seen something similar to this one in an article recently.

 

In 1977, I made my first (and only) sawhorses, still in use today, three states and five houses later.   I got the plan from Mother Earth News.   I bought a 8' 1x10 for legs and scrounged some 2x6 pieces from the scrap pile where they were building behind where I lived.   With a hand saw, chisel, and hammer, I got them together in the small basement of my apartment.   Legs were tapered (ripped the 1x10 at an angle) and flared in two directions.  I chiseled out where the legs attached to the top.  Used "spiral" nails.  And a couple of pieces of scrap 1/2" plywood for gussets.  Stackable.  Bob's your uncle.

 

Very similar to this one, but it just has the top beveled instead of a notch cut out

 

Mine are almost identical with the except the leg braces are closer to the top and on the inside. 
My pattern is from my Vo-Tech program in 1960

Yep.  Likely a few hundred variations of saw horses out there. I have a vague memory of seeing one with the top board cut to resemble a horses head and back, with a rope tail, and foot pegs sticking out of the legs. Might have been at a grandparent's house for the grandkids to play on. 

I designed and drew up the ones I linked to to stack or fold up, or even come apart down to flat pack for minimal storage or shipping.  I've made a set to hold up a 2'x4' butcherblock slab as a desktop, although I don't really need another desk. Those two I've taken apart and boxed up in anticipation for moving to a new smaller house this summer. 

4D

I invested $40.00 in a set of plastic Stanley horses.  Light, fold up thin and last outside for extended periods.  At the cost of lumber today they are a better choice.

 

My 2 Workmates are my saw horses. Today's hand saws don't fit my old, arthritic hands, anyway.

My Work Mates, as sawing supports, are used mainly in breaking down sheet goods. Most cross cuts are easier done at the miter saw. And, the Frankensmith handles the rips. 

As I age, motorized stuff has become very useful. 

Never had a use for one since I built the bench and it holds everything

3 hours ago, HandyDan said:

I invested $40.00 in a set of plastic Stanley horses.  Light, fold up thin and last outside for extended periods.  At the cost of lumber today they are a better choice.

I've had plastic shelves, plastic deck furniture, and likely have plastic all around me given it's prevalence.  Most is oil based, and called plastic because it is molded easily.   Plastic is a poor structural material and keeps proving that to me.   The shelves sagged once loaded.  The plastic chairs degraded in the sun, sagged, and cracked.  The plastic bits on the metal tools in my garage shop are the parts that have cracked and failed over time.  While plastic saw horses may support some load, I'll bet they aren't rated anywhere near as strong as plywood gusseted or steel saw horses are.  If they handle all your needs then fine.  The last time I used my single + WorkMate set I had all the sections from 9' wide solid wood garage doors on them.  Plastic saw horses I wouldn't have trusted to hold up that weight without buckling.    

 

4D

8 hours ago, HandyDan said:

I invested $40.00 in a set of plastic Stanley horses.  Light, fold up thin and last outside for extended periods.  At the cost of lumber today they are a better choice.

 

Got similiar.

1 hour ago, Artie said:

Got similiar.

ditto

Danl

2 hours ago, Danl said:

ditto

Danl

 

3 hours ago, Artie said:

Got similiar.

 

12 hours ago, HandyDan said:

I invested $40.00 in a set of plastic Stanley horses.  Light, fold up thin and last outside for extended periods.  At the cost of lumber today they are a better choice.

 

Me too four..can't leave them set up for long though...that little "shelf" quickly stores too much junk.

I choose wood over plastic for a few reasons.

Structural strength.  No way would I have set an auto body on a set of plastic horses.

 

 

I've had a couple sets of plastic horses, but found them too low.  My wood ones are sized to be the same height as my truck's tailgate when opened.  Use to anyhow, I need to make a new pair to match the Nissan.  This allows me to use the tailgate as a support on long stuff and sheet goods.  And too, the wood tops have more than a couple battle scars from saw blades.

You are braver than I Cal.  No way I'd crawl under that car.  Can't see the top of the saw horses but it doesn't look like there is anything other than friction between the legs and floor to keep them from doing the splits. Is there a chain between the legs that disappears in the photo perhaps? 

4D

I agree. I see no ties to keep those legs from spreading and I sure wouldn't get under to add any while that load is  on.

Edited April 16, 20224 yr by Al B

I was helping a friend/customer set up a warehouse and using some newer plastic sawhorses as scaffolding.  On there alone and one collapsed.  Fortunately I did not get hurt.

 

 

 

Fast, cheap, good : Pick two

 

Anyone have experience with the trestle-style sawhorses?

I have a pair of wooden sawhorses not too different from the ones Keith pic'd above, and I have a couple of sets of plastic ones that are used outside or for finishing. But none of them are the right height all the time, so I built a couple of wood boxes that can be laid on any side and hold things. These have turned out to be quite useful, and though they aren't used as often as my horses they are used quite a bit. I put fingers holes in 3 of the sides to make them easier to pick up. These are 9" x 19" x 22", I think it i did them over I'd make the 19" side a little shorter to give me a little more flexibility in heights. I'm sure I got this out of some woodworking magazine years ago but I can't remember which one. I did find a pic of my wooden horses, and you can see some dipwad cut into a top that had to be replaced...that dipwad would be me.

Edited April 17, 20224 yr by Fred W. Hargis Jr

22 hours ago, 4DThinker said:

You are braver than I Cal.  No way I'd crawl under that car.  Can't see the top of the saw horses but it doesn't look like there is anything other than friction between the legs and floor to keep them from doing the splits. Is there a chain between the legs that disappears in the photo perhaps? 

4D

 

Here is a better pic 4D.

 

 

Not sure where I conveyed the notion I was under the car.  I can assure you I was not.  I had other and better ways to work on the underside.

 

 

 

The right tool for the job...

1 hour ago, Cal said:

I had other and better ways to work on the underside.

 

You went all in on that.  Nice!!!!!!