Unleash Your Inner Craftsman: Construct Heavy-Duty Sawhorses Like a Pro

This is the plan download page for the Heavy-Duty Sawhorse Truck Camper Support shown in my YouTube video.

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Download the plan I used: Heavy-Duty Sawhorse Plan

Heavy-Duty Sawhorse Design

In this episode I’m going to build two new sawhorses. I already have a collection of them in various sizes. Some are simple and lightweight like these two for painting or these ones for most cutting and general carpentry. But I need to build a pair that can carry more load, specifically for storing our truck camper.

Heavy Duty Sawhorse for Camper Support A3
Heavy-Duty Sawhorse CAD Model

I’ll need them to support the approximately 4000 lb camper and be large enough to cover the dimensions of it’s base. So I’ll make the new sawhorses from 2×6 lumber. And as they will be outside most of the time, I’ll build them from pressure treated stock.

Heavy Duty Sawhorse for Camper Support A1
Measuring the ground clearance of the Truck Camper

I decided on a height of 30 inches with a length of 52 inches. That will cover the standard 48 inch width of the camper and have it supported high enough that I can still walk under the cabover bunk without hitting my head. And the stairs can still fold all the way down.

Heavy Duty Sawhorse for Camper Support A2
Overall size of the Heavy-Duty Sawhorse to support the Truck Camper

The sawhorses will relieve most of the load that the electric happy jacks carry. I’ll still have them in contact with the ground under enough load to help stabilize the camper. So it does not move when we are inside.

This sawhorse design is not a new idea. People have been building variations of this simple configuration for years. What I like about this design is it’s strength and simplicity. You don’t need any expensive tools to build these. A speed square and a circular saw can do all the cuts. And an impact driver and glue for assembly is really all you need.

Heavy Duty Sawhorse for Camper Support A4
Cutting the 2×6 pressure-treated lumber to build the Heavy-Duty Sawhorse

My sliding compound miter saw is overkill but it’s what I already have so I’ll do all the cuts on it. I’ll start by cutting the three pieces that make up the “I” beam top. A 52″ 2×6. Then a 48″ 2×4. And a 48″ 2×6.

I estimate that to make two sawhorses from my plans you would need to buy nine 8′ 2×6’s and one 8′ 2×4. There will be a bit of waste (but not much).

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Heavy Duty Sawhorse for Camper Support A5
Building the sawhorse on my workbench

I’ll mark a center line along the length of the top 2×6. Then drill 4 equally spaced 1/8th pilot holes.

Heavy Duty Sawhorse for Camper Support A7
Assembling the parts of the sawhorse

I used all GRK Screws on this build. The top of the legs will get some glue and the #10 x 4″ screws will be run in 5-1/2″ down the leg and into the 2×4, at the point where it makes contact with the leg.

Heavy Duty Sawhorse for Camper Support A9
Last few pieces glued and screwed on

I’ll apply some glue then screw this end stretcher to the legs and to the long sided stretchers. And for this I used #9 x 3-1/8″ GRK screws.

Sawhorse Support for Truck Camper

Heavy Duty Sawhorse for Camper Support A10
Lowering the Truck Camper onto the Heavy-Duty Sawhorses

With blocks added under the legs and the horses level I can lower the camper. And that seemed to work pretty well. The idea was to take some of the load from the happy jacks and add stability.

Heavy Duty Sawhorse for Camper Support A11
Adding diagonal supports that connect the sawhorses

Finally I’ll attach the sawhorses with two diagonal 2x4s. This will stiffen the supports front to back. The design of the sawhorses already provided stiffness side to side so I don’t think I need to do anything there.

Heavy Duty Sawhorse for Camper Support A13
Sawhorses adding support to the Truck Camper

I built these for a specific purpose but this simple strong-design for a sawhorse can be modified to suit almost anything. The height and length can be easily adjusted on the drawing to suit your needs.

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Why is it called a saw horse?

A saw horse is called so because it resembles a horse’s structure and is used as a support for sawing wood or other materials.

What is the difference between a sawbuck and sawhorse?

A sawbuck and a sawhorse are interchangeable terms used to refer to the same thing: a support structure used for cutting or working with wood.

Why do you need a saw horse?

To provide stability and support when cutting or working with large pieces of wood or other materials.

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