I once had a coworker who described his favorite sawhorses as Clydesdales. It was an appropriate name since his bulletproof horses seemed as heavy as their 1000-lb. namesake.
Another coworker had the opposite approach. He favored lightweight sawhorses made from six equal-length pieces of 2x4. He could bang a pair together in the time it takes to roll out an extension cord.
I think the best sawhorses are a combination of these two approaches. The best design I’ve found is the easy-to-build “Stackable site-built sawhorses
” from Ty Simmons of Fort Laramie, Wyo.
I like Ty’s horses because they’re lightweight and strong, and use common materials.
You could build them with only a circular saw, but using a tablesaw for beveling the top and a sliding miter saw for cutting the legs makes the process much easier.
Including setup, it took me about 90 minutes and cost me $50 in materials to make the pair of horses featured here.