A barbell weight bench affords the convenience of home workouts that can supplement your workouts at a fitness center. The bench can be sized to accommodate your particular body type, and plywood used as the platform. Pad the platform with chair cushions, or a custom vinyl pad that's made to your liking. Weld steel pipe to make the base and frame, and attach flat steel to risers for resting a barbell.
Step 1
Cut four pieces of 1 1/4-inch steel pipe as the sides and ends of the bench frame. Most weight benches are about 50 inches long and 16 inches wide. Weld the sides and end pieces at the four corners to make the rectangular bench frame.
Step 2
Cut two pieces of steel pipe 19 inches long as legs for the foot of the bench. Select one end of the frame as the foot and weld the legs perpendicular to the frame at the corners. Cut two pieces of steel pipe 52 inches long as front legs with risers.
Step 3
Stand the frame on the short legs and use wood blocks to support it in a level position. Tack-weld the 48-inch risers to the corners at the head of the bench frame. Check the frame for level and make any adjustments as needed so the frame is level from end to end and side to side. Make full welds to attach the front legs with risers.
Step 4
Use the circular saw and cut a piece of 5/8-inch plywood as the bench platform. Align the plywood on the bench frame and drill 1/8-inch pilot holes through the plywood and into the top of the steel pipe frame. The pilot holes should be about 6 inches apart. Attach the plywood to the bench frame with sheet metal screws at each pilot hole.
Step 5
Cut four pieces of 1/8-inch rolled steel 2 inches long as pairs of barbell rests. Weld these at an upward angle to the face of each riser. The spacing of the paired rests should be 24 inches and 30 inches above the surface of the bench.
Step 6
Cut a piece of 1 1/4-inch steel pipe as a horizontal stabilizer that fits between the risers. Weld the stabilizer just below the top of the risers. Buff the welds using a wire wheel attachment in the electric drill.
Tips and Warnings
- Select a larger or smaller diameter of steel pipe if desired. Prime and paint the steel frame before attaching the plywood. Use rubber furniture coasters to pad the legs of the bench. Add a padded cross piece at the foot of the bench for stomach exercises.
- Do not attempt to weld without experience or supervision. Wear eye protection when cutting and drilling steel pipe.
Things You'll Need
- 1 1/4-inch steel pipe
- Hacksaw
- Welding equipment
- Wood blocks
- 24-inch level
- 5/8-inch plywood
- Circular saw
- Electric drill
- 1/8-inch drill bit
- Pan head sheet metal screws
- Screwdriver
- 1/8-inch rolled steel, 3/4-inch wide
- Wire wheel attachment
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