Every woodworking shop needs a good pair of sawhorses. But with a simple upgrade using pipe clamps and a 2x6, you can turn an ordinary sawhorse into an adjustable-height work support that's useful for a variety of tasks around the shop.
In my small shop, I'm always looking for ways to make better use of the space and get more functionality out of the tools I already own. This adjustable sawhorse is a good example. By adding a raised platform supported by two pipe clamps, I can change the working height to suit the job rather than being limited to the fixed height of a traditional sawhorse.
The adjustable platform is especially handy as extra support when ripping long boards or cutting sheets of plywood on the table saw. I can simply raise or lower the platform to match the saw's table height. With two modified sawhorses, I can also set up a temporary assembly or finishing surface at a comfortable working height.
How to Make an Adjustable-Height Sawhorse
Adding the adjustable platform is a straightforward upgrade. I started by drilling two 1 1/8"-dia. holes through the top of my sawhorse. These holes accommodate the 3/4" pipe used for the supports.
The platform itself is made from a length of 2x6. To connect it to the pipes, I attached a pair of threaded pipe floor flanges to its underside. An easy way to locate the flanges is to insert the pipes through the holes in the sawhorse, thread a flange onto each pipe, and position the platform on top. Then fasten the flanges securely to the 2x6 with flathead woodscrews.
Once the platform is attached, install the movable jaw of a pipe clamp on each pipe below the sawhorse top. The jaws support the pipes and allow you to adjust the platform's height. To raise or lower it, reposition the jaws on the pipes until the platform is where you need it.
It's a quick way to get more versatility out of a pair of sawhorses without taking up additional floor space. Just be sure the jaws are securely engaged and the platform is stable before putting it to work.
