A pair of sawhorses and a sheet of plywood makes a workstation anywhere. Sawhorses support material for cutting, hold assemblies during glue-up, serve as scaffolding bases, and provide a work surface when you do not have access to a permanent workbench. Here are the options and how to choose.

Sawhorses and Work Supports

Types of Sawhorses

Folding Metal Sawhorses

The most popular choice. Steel or aluminum frames that fold flat for storage and open in seconds. Typical capacity: 1,000 to 1,300 pounds per pair. Models from Stanley, DeWalt, and Toughbuilt cost $30 to $80 per pair. Look for wide-stance legs and non-slip feet.

Plastic Sawhorses

Lightweight, inexpensive, and stackable. Adequate for light work like painting and assembly. Not stiff enough for heavy cutting or as stable as metal. Good for painting projects where drips and spills are expected.

Wooden Sawhorses

The traditional choice. You can build a pair from 2x4 lumber in under an hour. Strong, customizable, and expendable — you can cut into them, drill into them, and screw jigs to them without concern. Every workshop should have at least one pair of wooden sawhorses.

Speed Horses (Bracket Type)

Metal brackets that accept 2x4 lumber for the top beam and legs. Build a pair in minutes for a few dollars in lumber plus the brackets. Adjustable leg angles and easy replacement of damaged pieces. TheDERA and Hopkins brands are widely available.

Work Heights

Standard sawhorse height is 32 to 34 inches, which puts a full sheet of plywood at a comfortable working height for cutting. For assembly and bench work, 36 inches is more ergonomic for standing tasks.

If you build your own sawhorses, customize the height to your body. Your wrists should rest comfortably on the work surface with your arms hanging naturally at your sides.

Supporting Sheet Goods

Cutting a 4x8 sheet of plywood requires proper support on both sides of the cut:

Place two sawhorses parallel, about 4 feet apart
Set rigid foam insulation board (2-inch thick) on top of the sawhorses
Place the plywood on the foam
Cut through the plywood and slightly into the foam with your circular saw

The foam supports both sides of the cut, preventing the sheet from pinching the blade or falling. This setup handles most sheet-good cutting without a table saw.

Roller Stands

A roller stand is a height-adjustable support with a roller on top. Position it at the outfeed end of your miter saw or table saw to support long boards as they exit the cut. Without outfeed support, long boards tip, bind, and create dangerous kickback situations.

A quality roller stand costs $25 to $50 and is one of the simplest ways to improve safety on a table saw.

Work Support Clamps

Clamping workpieces to sawhorses holds them securely for cutting and assembly. Quick-grip clamps grab the material to the sawhorse beam in seconds. For repeated use, bolt a strip of wood to the sawhorse beam with a slot for a clamp, creating a built-in clamping station.

Portable Workbench

Products like the Black and Decker Workmate combine sawhorses, a vise, and a work surface in a folding, portable unit. They clamp irregular objects, hold doors for edge planing, and provide a stable surface in the field. Useful for apartment dwellers and those without a dedicated workshop space.

Bottom Line

Start with a pair of folding metal sawhorses and build a pair of wooden ones when you have time. Add a roller stand when you set up a miter saw or table saw. This simple collection of supports makes every cutting and assembly task safer, easier, and more accurate.