You can spend more than $100 on a basic weight bench, which seems like a lot for a board on four legs. Alternatively, you can build your own weight bench out of lumber using tools you likely have at home. Set aside an afternoon for this project. Although it may take only an hour, you should give yourself time to do it slowly and right. Accidents on an uneven or wobbly weight bench can cause serious injuries.
Preparation
Step 1
Cut the plywood sheet to 48 inches by 18 inches using your power saw.
Step 2
Cut the 4-by-4 inch post into four lengths, each 18 inches long. Measure these as exactly as possible, since uneven posts will lead to a wobbly bench.
Step 3
Cut your beams into four sections. Two sections should be 18 inches long, the other two 45 inches long.
Step 4
Sand your plywood using rough-grit sandpaper. You can sand the other lumber as well, but it's not necessary for this design.
Step 5
Cut the foam pad to 48 inches by 18 inches using your craft knife.
Step 6
Cut the vinyl sheet to 52 inches by 22 inches.
Build the Bench
Step 1
Set one 18-inch beam and one 45-inch beam in an L, the end of the long beam abutting the inside face of the short beam. Screw them together using two wood screws.
Step 2
Repeat step one to build a second L.
Step 3
Arrange the two Ls in a rectangular frame. Screw them together with two screws at each joint, as you did with the original Ls.
Step 4
Set the plywood sheet down on top of your frame. Screw it in place with one wood screw in each corner. Reinforce with one wood screw on center for each short side, two evenly spaced wood screws for each long side.
Step 5
Set one of your 18-inch posts in a corner formed by the beams at the underside of your frame. Screw it in place with three wood screws driven through the plywood and into the end of the beam. Reinforce this with one screw driven through the 45-inch beam and into the side of the post.
Step 6
Repeat Step 5 three more times, adding another post to each of the remaining corners.
Padding
Step 1
Set the bench on the free ends of your posts.
Step 2
Apply a thin coat of wood or craft glue to the top of your exercise bench. Immediately place the foam pad on top of the bench, its edges aligned with those of the plywood. Allow it to dry.
Step 3
Reinforce the glue by stapling the foam pad in place. Use three lines of eight staples each, running the long way down the pad.
Step 4
Place the vinyl sheet on top of the pad, each side overlapping the edges of the pad by 2 inches.
Step 5
Use your craft knife to cut four slits in the vinyl. Each slit should run from the corner of the bench to the corresponding corner of the vinyl sheet.
Step 6
Fold over one short end of the vinyl. Staple it to the side of the beam using a line of six evenly spaced staples.
Step 7
Pull the other short end over the opposite side of the bench, stretching the vinyl tight. Staple it in place as you did the first short end.
Step 8
Stretch one long end of the vinyl over its side. Staple it in place with a line of 16 evenly spaced staples. Repeat to attach the final free side.
Tips and Warnings
- Use this bench for dumbbell and light barbell workouts. For power lifting with barbells, it's safest to use a commercial-grade, steel tube exercise bench.
Things You'll Need
- Plywood sheet, 3/8 inches thick
- Wooden post, 4 inches by inches
- 2 wooden beams, 2-by-4 inches
- Dense foam pad, camping-style
- Sheet of vinyl
- Wood screws, 2 inches long
- Finishing nails
- Power saw
- Power drill
- Staple gun with heavy-duty staples
- Craft knife
- Wood or craft glue
References
- "Step by Step Basic Carpentry"; Ben Allen; 1997
- Ben Cohn; Fitness Coach; Hillsboro, Oregon
- Mike Byers; General Contractor; Corvallis, Oregon
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