I thought may be the humble saw horse needed a thread of it's own. Next to a good table they're some of the handiest things to have around the shop. Hell, you can even use them as a base for a fab table. I also think building them would make a good basic welding project for shop classes.
Any way I've probably built 15 pairs of them in just the past 6 months and think I've got a pretty good system figured out. A simple CAD side view drawing of the legs gives me all the information I need to make them what ever finished height is desired. So far 18, 24, 30, 34 and 36 inch have been the heights I've found most useful. For leg angles I've been using 30/60 for the shorter ones and 70/20 for the taller. For material I've mostly been using 2" square, .125 wall for the legs and 2 x 4 x .188 (or .250) wall for the horizontal cross member. So far I've just built them out of steel tube but I'm guessing that before the year is out I'll build an aluminum pair.
If any one else has any thoughts or opinions on building saw horses (or pictures of ones they've built) feel free to jump in.
A couple of general pictures first.....
With the addition of some good non-swiveling casters these have been turned into some pipe roller stands. Depending on future projects I can for see some of these getting the wheels taken back off of them.