Pulley system add-on, easily add weight plates

Anyone who has ever used one of these pulley systems knows it is a bit of a pain to change weights. Luckily, there is an easy fix. 

A recent post by Garage Gym Experiment, showed a simple add-on that allows easy access to the weight plates. The original idea is from David Kerkes. It was a diy project for his home gym. 

Brilliant idea, but no one is making or selling these. Well, with David’s permission, I made this tutorial. 

Tools:

Dewalt sliding mitre saw - Amazon link (https://amzn.to/3pdqFe3), Home Depot link (https://homedepot.sjv.io/3P7GRB)

Dewalt cordless drill - Amazon link (https://amzn.to/3g2VM7L), Home Depot link (https://homedepot.sjv.io/doRm3K)

Bosch cordless drill set - Amazon link (https://amzn.to/2TGLLpz)

Drill press - Amazon link https://amzn.to/3wh8beK), Home Depot link (homedepot.sjv.io/doRm3K) - alternatively, the holes can also be drilled using a cordless drill

2 inch forstner bit - Amazon link (https://amzn.to/2RXrIT2) , Home Depot link (homedepot.sjv.io/2rKENG)

1.75 inch forstner bit - Amazon link (https://amzn.to/3gGf6Ix) , Home Depot link (homedepot.sjv.io/RyRBVy)

Materials:

1 x 6 board - Home Depot link (homedepot.sjv.io/kjReqv)

1.75 inch round dowel  (or 1.5 inch dowel if you can’t find 1.75) - Home Depot link (https://homedepot.sjv.io/n1nGPM)

2 inch screws - Home Depot link (homedepot.sjv.io/zajEV7)

Bumper plates are about 18 inches long, so I cut my 1x6 to 17.5 inches. 

I find center and drill a 2” hole with a forstner bit. 

I use a 10 pound weight plate to figure out where my dowels should go. 

It’s about 3 inches from the end of the board on both sides. 

I use a 1.75” bit to make insets for the dowels. These are not very deep. 

Then I use a small drill bit and go all the way through in the center. 

My dowels are 1.75 inches. I cut 2 six inch pieces of the dowel. 

Routing everything is completely optional, but I just love how it makes stuff look so much nicer and it’s pretty quick. For this, I am going over all the edges with a quarter inch round over bit. 

I do some quick sanding 

Pre-drilling into the dowels help the screws go in easier. 

I add some wood glue before placing the dowel, then add a 2 inch screw. Repeat on the other side. 

A quick little spray and it’s ready to go. 

This post is not sponsored. Some of the links are affiliates which means if you purchase through the link, I’ll receive a small commission.

If you like this, check out my other home gym diy projects. 

Do you have an idea for my next build? Leave a comment below!

If you build this, I’d love to see it! Tag #kaizendiygym on Instagram and I’ll feature it on my page!

https://www.instagram.com/kaizendiygym

@kaizendiygym