DIY Folding Sawhorse Exploded Plan with Full Parts List and Dimensions

A folding sawhorse is one of the most useful shop projects any woodworker or DIY builder can make. It gives you a stable cutting platform, folds flat for storage, and can handle everything from sheet goods to framing lumber. This fully detailed folding sawhorse plan includes the complete parts list, hardware specs, measurements, and assembly breakdown needed to build a durable collapsible sawhorse from scratch. Access over 16,000 woodworking plans 

Whether you are setting up a garage workshop, building a mobile jobsite setup, or simply want reliable support stands for woodworking projects, this folding sawhorse design combines strength, portability, and simplicity in one build.

Why Build a Folding Sawhorse?

Unlike fixed sawhorses that take up permanent floor space, folding sawhorses collapse flat when not in use. That makes them ideal for small workshops, garages, sheds, or mobile construction work.

This design uses:

• A solid 30 inch top beam
• Four angled legs for stability
• Dual stretchers for rigidity
• Folding pivot hardware
• Simple dimensional lumber
• Basic woodworking tools

The folding mechanism locks tightly when opened while still allowing smooth collapsing for transport and storage.

Finished Dimensions

The completed folding sawhorse measures approximately:

Part	Measurement
Overall Height	30 inches
Top Beam Length	30 inches
Width at Base	24 inches
Leg Angle	75 degrees
Stretcher Length	26 inches
Folded Thickness	About 5 inches

These proportions create a stable work platform while maintaining a compact folded profile.

Materials List

You can build one sawhorse using standard construction lumber.

Lumber Required

• 1 × 2x6 board at 8 feet long
• 2 × 2x4 boards at 8 feet long

Hardware Required

• 4 carriage bolts — 3/8 inch × 4 inch
• 8 fender washers
• 4 lock nuts
• 16 wood screws — 2.5 inch
• Wood glue (optional)

Using carriage bolts with fender washers ensures the folding legs pivot smoothly without loosening over time.

Complete Cut List

Top Beam

Quantity	Size
1	30 inch 2x6

Legs

Quantity	Size
4	32 inch 2x4

The legs are cut with opposing 15 degree bevels to create the final 75 degree stance angle.

Stretchers

Quantity	Size
2	26 inch 2x4
2	26 inch 2x4

Two stretcher assemblies help prevent racking and twisting during use.

Folding Mechanism Explained

The folding action is created using pivot bolts mounted through the upper section of each leg assembly.

Hardware Stack Order

For each pivot point:

1. Carriage bolt
2. Fender washer
3. Outer leg
4. Beam spacer area
5. Inner leg
6. Fender washer
7. Lock nut

The washers reduce friction and protect the wood from wear during repeated folding.

Do not overtighten the lock nuts. The legs should pivot freely while remaining snug without wobble.

Step-by-Step Assembly

Step 1 — Build the Top Beam

Cut the 2x6 beam to 30 inches. Sand all edges smooth and slightly round over the corners for comfort and durability.

Mark pivot locations evenly from each end.

Step 2 — Prepare the Legs

Cut all four legs to length with 15 degree bevel cuts on both ends.

This creates the final 75 degree angle once assembled and gives the sawhorse a wider stable footprint.

Step 3 — Drill Pivot Holes

Clamp each pair of legs together and drill the carriage bolt holes through both pieces simultaneously to guarantee alignment.

Install:

• Carriage bolts
• Fender washers
• Lock nuts

Test the folding action before continuing.

Step 4 — Install Stretchers

Attach the 26 inch stretchers between the legs using wood screws.

One stretcher set mounts higher while the second set mounts lower for added rigidity.

This creates a strong braced frame that prevents side sway.

Step 5 — Final Assembly

Attach the completed leg assemblies to the beam and verify:

• Legs fold smoothly
• Sawhorse stands level
• Hardware remains tight
• No wobble exists under load

Sand all surfaces and apply paint, stain, or clear finish if desired.

Tips for Stronger Construction

For maximum durability:

• Use kiln dried lumber
• Predrill screw holes to avoid splitting
• Add glue to stretcher joints
• Use exterior screws if stored outdoors
• Apply polyurethane for moisture protection

A properly built folding sawhorse can easily support heavy plywood sheets, framing material, and power tool work.

Best Uses for a Folding Sawhorse

This design works perfectly for:

• Circular saw cutting stations
• Portable workbenches
• Painting supports
• Construction sites
• Woodworking shops
• Garage workshops
• Outdoor DIY projects

Build two matching sawhorses and pair them with a plywood sheet to create a temporary work table anywhere.

Final Thoughts

This DIY folding sawhorse plan combines portability, strength, and simple construction into one practical woodworking project. The angled legs, reinforced stretchers, and bolt pivot system create a sturdy work support that folds flat in seconds for easy storage.

For beginner woodworkers, this is an excellent weekend build that teaches accurate measuring, angled cuts, hardware installation, and structural assembly techniques while producing a tool you will use for years.