Folding Sawhorses | STEP BY STEP with limited tools
In this video, I’ll show you step-by-step how to make a pair of space-saving, folding sawhorses.
Start by cutting the legs from 2x4s. TIP: Make sure to get kiln-dried (KD) and take your time to find the straightest boards you can.
Set your circular saw to cut a 22.5-degree bevel for the leg cuts. Use your first leg piece as a measuring stick for the other cuts.
After cutting the legs, adjust your saw back to normal and shave off an additional 3mm from the top of each leg. This keeps the hinge from sticking out.
Use a pocket hole jig to drill 2 screw holes in the top of 2 of the legs for each sawhorse.
Connect the legs with the hinges.
Now cut cross braces out of 1x2s, one for each sawhorse. Make 2 pocket screw holes on the end of each brace. Screw onto leg pieces, aligning with the bevel on top of boards.
Cut the top board out of another 2×4, and use previously-drilled pockets to screw top onto legs.
To cut leg braces out of 1x2s, measure halfway up the leg of your sawhorses, and then measure the distance between your two legs.
If desired, round the ends of these boards. Make sure to work around any knots or rough edges of your board. Then drill a hole at each end to bolt it in place.
On one end, cut a notch wide enough for a ¼” bolt to drop into.
The hinged side of your leg brace should be on the hinged leg of your sawhorse. Don’t drive your bolt in so tight that the brace won’t swing.
Use ½” plywood for the shelves. Screw onto braces.
Now enjoy your sturdy, handy, space-saving sawhorses! 
Plans:
WWMM Folding Sawhorses (sketchup)
