Sawhorse height calculator
A sawhorse that's too tall has you reaching down to cut; one that's too short has you bent over. The right height depends on whether you're cutting with a hand saw (lower) or breaking down sheet goods with a circular saw (higher), and how heavy the workpiece is.
Calculator
Why hand saws want lower horses
A hand saw cuts on the push stroke, with your shoulder providing force. The sawhorse should be at knuckle height — let your shoulder do the work, not your back. Power tools are different: the tool provides the cutting force, and you want the workpiece up where your hands can guide it.
Fixed vs folding
Home-center folding sawhorses are 28–30″ tall — short. They're built for trim carpenters who want something to lean a board against while cutting with a hand saw. For a woodworker doing heavier work, fixed heavy-duty sawhorses at 32–36″ are a better choice. They're harder to store but rock-solid under a slab.
The weight consideration
Heavy workpieces don't change the height — your body's geometry stays the same. But they do change the design. A 100-lb slab on a wobbly folding horse is dangerous; on a fixed horse with a wide top it's stable. The calculator's height recommendation is the same; the construction method is the variable.
Limitations
- Height is a starting point; your body's geometry matters more than the rule of thumb.
- Doesn't model the workpiece thickness — adjust for that.
- Doesn't account for the cut type; angled cuts may want slightly different heights.
- For an adjustable horse, build to the high end and accept compromise.
Frequently asked questions
What about a stand for breaking down plywood?
Plywood break-down is the most punishing task. The horses need to be tall (workpiece at elbow height), wide (sheet goods need 3+ feet of support), and lockable (you don't want a sheet sliding off). Build or buy dedicated sheet-goods stands; folding horses are too narrow.
Should I build my own or buy?
Build if you'll use them weekly. Buy if you'll use them monthly. A set of heavy-duty folding horses from a tool brand runs $80–150; building fixed heavy horses costs $30 in lumber and an afternoon. The decision is how often you'll use them.
My back hurts after cutting on the horses. Why?
Either the horses are too low (you're bent over) or too high (you're reaching down with your arms). Adjust by 2–4″ and try again. If you can't adjust, you may be using the wrong task type for the height.