The original sawhorse design was a great one, the only things I really changed for the 2.0 version were the height of the horses, the width of the horses, and the width of the leg panels. The changes made now allow for nearly, if not all of the materials to be cut out of one sheet of plywood (on the computer it says it can be done, but when I tried I failed somehow). The working height could be lowered still to enable you to get everything out of one piece except for the 2x4 top piece, but that would lower the working height to a level to low for my personal preference.
The working height in version 2.0 is approximately 31" which uses a leg panel height of 28", and the width of the sawhorses are nearly 43". The width of a leg panels is 5" which allows you to cut two leg panels out of a 48"x33" section of 3/4" plywood. It may be difficult to understand but I will have a image of the cut list soon which will help clear everything up.
Everything else is the same as the original version.
I built a set of these about three of four weeks ago and have been using them on remodeling and construction jobs and they are holding up great. I have had easily over 100 8' pieces of tongue and groove pine on them along with a miter saw and they never showed any signs of weakness. Everyone who comes to the jobs takes a close look at the sawhorses and asks my boss man where he got them, it feels good when he points at me and says "He built them, not me".
The construction is pretty simple and I think you should be able to simply recreate your own. I did however make a cut list type thing on Sketch up that shows how you can get the pieces easily out of one sheet of plywood.
The "U" shaped leg panels are 28" tall and about 42 15/16" long and 5" wide on all three segments. When it is laid out on a sheet of plywood I center my saw blade on the line since I am using both pieces on either side of the blade.
The rest is pretty easy, 6 pieces 3" x about 42 15/16" (four of them with an 18* bevel cut down one long side) and 4 at 2". Then from the inside of a leg you cut 8 pieces that are used for the inside of the legs for support.
Here is a video helping with the building process. I go into some detail about assembly and remind you of a few things, check it out.
More detailed photo's and descriptions are availiable in this post that should aid in the the building process.
If anyone has and questions of comments feel free. Don't forget about The Woodworking Trip, there should be a video on these things coming soon. Thank you!
