DIY Adjustable Height Sawhorse Workbench — Full Build Plans

DIY Adjustable Height Sawhorse Workbench — Full Build Plans

Overall Dimensions

  • Workbench Length: 1200mm (120cm / 47.2")
  • Adjustable Height Range: 700–900mm (70–90cm / 27.5–35.4")
  • Base Depth: 600mm (60cm / 23.6")
  • Leg Thickness: 60mm × 60mm
  • Top Thickness: 40mm recommended access over 16,000 Woodworking plans 

Designed for:

  • Portable jobsite use
  • Assembly work
  • Cutting station support
  • Temporary outfeed table
  • Compact workshop bench

Main Structure Overview

Front View

      ┌──────────────────────┐
      │      TOP FRAME       │
      └──────────────────────┘
        │                │
        │ Adjustable     │
        │ Inner Legs     │
        │                │
     ┌──┴──┐          ┌──┴──┐
     │Outer│          │Outer│
     │Leg  │          │Leg  │
     └─────┘          └─────┘

Materials List

Timber

Main Frame & Legs

  • 60×60mm hardwood or structural pine

Top Surface

  • 18–25mm plywood or laminated hardwood

Cutting List

Top Rails

  • 2 × 1200mm

End Rails

  • 2 × 480mm

Adjustable Inner Legs

  • 4 × 650mm
  • 60×60mm timber

Outer Sleeve Legs

  • 4 × 600mm
  • Built from:
    • 90×90mm timber drilled out
    • OR laminated box sleeves from plywood

Lower Stretchers

  • 2 × 1050mm

Feet

  • 2 × 600mm

Height Adjustment System

Pin Lock Mechanism

Use:

  • 12mm steel locking pin
  • Hitch pin
  • Or removable bolt system

Hole Spacing

Drill holes every:

This gives multiple height positions between:

  • 700mm
  • 750mm
  • 800mm
  • 850mm
  • 900mm

Leg Sleeve Construction

Option 1 — Timber Sleeve

Use:

  • 90×90mm posts

Drill centered holes for locking pins.

Option 2 — Plywood Box Sleeve

Build square sleeve from:

  • 18mm plywood

Internal Opening

Approximately:

Allows smooth sliding for 60mm legs.

Top Dimensions

Work Surface

  • 1200mm × 450mm

Optional:

  • Replaceable sacrificial top
  • Bench dog holes
  • T-track system

Assembly Steps

1. Build Top Frame

Assemble:

  • Two long rails
  • Two end rails

Check for square before fastening.

2. Construct Adjustable Legs

  • Insert inner legs into sleeves
  • Drill matching adjustment holes
  • Install lock pins

3. Attach Stretchers

Install lower braces between legs.

This prevents wobble during cutting.

4. Install Top

Secure plywood or hardwood surface to frame.

Recommended Hardware

  • 75mm wood screws
  • Wood glue
  • 12mm hitch pins
  • Washers
  • Lock nuts

Optional Add-Ons

Folding Legs

Add heavy-duty hinges for portability.

Tool Shelf

Lower shelf between stretchers.

Clamp Slots

Cut side notches for quick clamping.

Wheels

Add retractable casters.

Stability Tips

  • Keep feet slightly wider than top.
  • Use diagonal braces if using softwood.
  • Round over edges for comfort.
  • Wax sliding leg sections for smoother adjustment.

Ideal Uses

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