DIY Network

	Figure A
	Figure B
	Figure C
	Figure D

• To mark the notches for the legs of the sawhorses, lay out an 8" piece of 2x4. Measure and mark 2" in from each end and about 3/4" up from the bottom edge (figure A).

• On the opposite edge of the 2x4 piece, measure and mark the center of the board length. Measure and mark 3/4" to the either side of the center mark and 1" from the edge of the board.

• Check the measurements. There should be marks for a long notch along one edge of the board and a shorter notch along the other edge. Both should be centered lengthwise on the board.

• Cut out the notches (figure B). Michele Beschen used a band saw. If a band saw is not available, make several cuts down into the notches with a hand saw and then chisel out the excess wood.

• Create the other three legs in the same manner.

• Set the legs on a work surface with the small notches facing up. Use a 3/16" wood bit to drill a hole down through the center of the small notch in each leg piece (figure C).

• Position two of the legs about 14" apart with the small notches facing up. Dry fit a 16" 2x4 into the small notches; it should be a snug fit (figure D). If the 16" piece won't fit into the notches, sand the notches as needed.

• Apply wood glue to the small notches of both legs and insert the 16" piece to connect the legs. The 16" crosspieces should extend about 1" past each leg.

• Flip the assembly over and use the pilot holes to secure the crosspiece to the legs with 3" decking screws.

• Assemble the other sawhorse in the same manner.