The ultimate sawhorse should be light as a feather, strong as reinforced concrete, have infinitely adjustable height and collapse to the size of a Swiss-army knife. My design using 1-1/2-in. and 1-1/4-in. square steel tubing hasn’t been refined quite to that point, but it sure beats most of the 2×4 or plywood types
This horse is fairly light, very strong and will nearly double its collapsed height. The 1/2-in. bolts bind the sliding cross bar tight enough to support lots of weight. The adjustable foot assembly on all four corners takes the wobble out of the horse on uneven concrete floors and allows a screw or nail to be sunk through the nut to hold the horse in place on a construction-site subfloor. Because they nest together, the horses don’t take up much room during transport.
Cut the tubing with a hacksaw, reciprocating saw or with an abrasive blade mounted in a radial-arm saw or power miter saw. If you don’t have a welding setup, you can keep the cost of the actual welding at a reasonable level by cutting, deburring and drilling the pieces yourself.
Brooks Heard, Moscow, ID