To begin building the Ultimate Wood Sawhorses, begin by cutting a 2x4 into two pieces, one at 47-inches and the other piece at 49-inches. Repeat this step twice, so you have three of each size.
Next, we'll assemble the I-Beam as shown above, starting with the three 49-inch boards. On the ends of two of the boards, mark a centerline across the short axis of each end, as shown by the top and bottom boards in the diagram. When those four marks are in place, mark a centerline down the long axis at each end of the third board, as shown by the center board in the diagram.
Now, using the screws, attach the top board to the center board. Place a few screws down the length of the top board and into the center board, making certain to keep the centerlines on both ends aligned. When the top board is attached to the center board, flip the assembly over and attach the bottom board in the same manner. When complete, you should have a long I-Beam.
Repeat the entire process with the 47-inch boards.