Shop-Made Benchtop Sawhorses for Easy Workpiece Support
There are plenty of times in the shop when it's helpful to raise a workpiece above the workbench. Whether you're making a cut with a circular saw, routing an opening, or assembling a project, having a little clearance underneath the work can make the job much easier.
That's why I keep several benchtop sawhorses close at hand.
These compact supports are made from strips of 3/4" plywood. They're easy to build, simple to clamp in place, and sturdy enough for a variety of everyday woodworking tasks.
Best of all, they protect the workbench surface while giving you more room to work.
Simple Plywood Sawhorses for Your Workbench
Unlike full-size sawhorses, these small supports are designed to sit directly on top of a workbench.
Each sawhorse has a top and bottom plate connected by a vertical plywood support.
The wide plates serve two purposes. The bottom provides a convenient place to clamp the sawhorse to the bench, while the top gives you room to clamp the workpiece securely in place.
That means you can hold a board or assembly above the benchtop without having to balance it on scraps or improvised spacers.
Build the Supports from 3/4" Plywood
You don't need much material to make a set of these handy supports.
Start with strips of 3/4" plywood and cut the top plates, bottom plates, and vertical supports to size.
Assemble the pieces to form a sturdy, raised support. Keep the top and bottom plates aligned so the sawhorse sits flat and provides a stable surface for the workpiece.
I like to make several sawhorses in different lengths. Shorter versions are convenient for small parts, while longer ones provide more support for larger boards and assemblies.
Having a few sizes on hand makes it easy to choose the right setup for the job.
Protect Your Workbench While Cutting and Routing
One of the biggest advantages of these benchtop sawhorses is the clearance they provide beneath a workpiece.
When cutting through a board or plywood panel with a circular saw or jigsaw, the supports keep the blade away from the benchtop.
They're also useful for routing operations that require clearance beneath the workpiece.
Position the sawhorses so they're clear of the cutting path, and clamp them securely to the bench. Make sure the workpiece is supported on both sides of the cut, with enough clearance for the blade or router bit.
For through-cuts, arrange the supports so the offcut won't fall, shift, or pinch the blade as the cut is completed.
Handy Supports for Assembly and Glue-Ups
These small sawhorses aren't limited to cutting operations.
They're also great for raising project parts and assemblies above the bench.
The extra clearance makes it easier to position clamps around an assembly, reach underneath a workpiece, or work on the edges of a panel.
I also like using them during glue-ups.
A light coat of paste wax on the support surfaces helps keep glue squeeze-out from sticking to the plywood.
That makes cleanup easier and prevents an assembly from becoming glued to the supports.
A Simple Shop Accessory You'll Use Again and Again
Sometimes the most useful shop accessories are also the easiest to make.
With a few strips of plywood, you can build a set of compact benchtop sawhorses that make cutting, routing, clamping, and assembly more convenient.
Make several in different lengths and keep them within easy reach. When you're finished, they can be stored out of the way until the next project.
They're a small addition to the workshop that can make a big difference in how easily you work.
More Woodworking Tips & Tricks
These benchtop sawhorses are just one example of how a few scraps of wood can become a useful workshop accessory.
Discover more practical woodworking tips, clever workholding solutions, shop-made jigs, and time-saving techniques that help you get more from your tools and workbench.
EXPLORE MORE WOODWORKING TIPS → Simple Shop Solutions That Make Woodworking Easier
