I just finished experimenting with a couple of new designs for saw horses. These aren't going to support a tremendous amount of weight, but I wanted some lighter saw horses to set up temporary tables in the garage, for when I have others over to work on projects.
One set of these is meant to take the LEAST amount of wood possible for a sawhorse. These take just a little over 2.5 standard studs (2"x4"x8') each in material.
Both sets are meant to stack in the smallest space possible. Notice one leg on each sawhorse is offset the width of a 2x4 from the end, so the legs don't get in the way of each other when you are storing them.
The last pic is a rendering, from my 3D design program, for the minimalist saw horse.
Most of the joints use pocket holes to attach the pieces together (except the diagonal braces, which are just screwed directly through the material).
They are surprisingly sturdy and are very light and easy to move around.
Kev