Heavy Duty 2x4 Sawhorse Brackets

thingiverse

These are robust sawhorse brackets for 2x4s. Only 90-degree cuts are required. It is strong enough that you could probably make these out of PLA, but I used ABS. (Update - I also added a mini version which is lighter duty but uses much less filament.) Sawhorse_bracket is the main piece. Each one should be printed with Sawhorse_feet (which will print 2 feet) unless you want to make 15-degree cuts so that the 2x4 legs sit flat. Sawhorse_brace is an optional bracket for adding additional cross support to the sawhorse legs, or for mounting a small shelf. The Sawhorse_brace-mini is required when using the mini bracket since the mini bracket would experience much higher torque due to the shortened 2x4 socket. According to my slicer, each full sawhorse (2 brackets, 4 feet, 4 braces) costs $15.60 @ $20/kg material cost. I like to think this is as strong as the 2x4 Basics' brand sawhorse kit which runs $25 on Amazon. Keep in mind you will need more than one 1kg roll of filament to make a pair of these sawhorses. For the mini version, each full sawhorse (2 brackets, 4 feet, 4 braces) costs $9.77. So a pair of them can be made with a single 1kg spool. The model includes support material - please disable auto-support when printing. I also recommend rotating the model 45 degrees around Z (top view) for the built-in support to work best. This will force the printer to lay down the first top layer perpendicular to the supports. Use 2 perimeters, 4 bottom/top layers, and 17% infill if using cubic, or at least 22% if using grid for best results. If you are using grid or rectangular infill, and have rotated the model 45 degrees - have infill run at 0 and 90 degrees instead of the default 45/135. Adding a brim and 101-102% scaling is recommended for ABS. Instructions: Use 1.5" standard wood screws I made my legs 30", the top piece 26", and the brace piece 10" so that each sawhorse used a single 8' 2x4. It's easiest to secure the feet onto the 2x4 legs first, then attach the legs to the bracket. If you're using the brace, secure both printed brace parts to the 2x4 brace piece you cut before attaching it to the legs.