Outdoor Pull-up Bar

Outdoor Pull-up Bar

Do you want to buy a ready made free standing pull up bar? …..or do you want to be able to workout outside, with homemade body weight equipment meeting your own custom design? This guide will provide you a basic construction approach, which can be used to build DIY : Outdoor pull up bars Dip bars General body weight training equipment …all to your own custom specs. Tools & Materials Shopping List As the guide is intended for a custom setup; this shopping list does not generally specify quantity and sizes but where relevant links to material of most typically used sizes. Read through the guide once, decide on your design, then come back to this section again. Use this as a handy reference for any tools or materials, which you don’t already have. Materials Pressure Treated Posts (3′ of post in the ground) Quickrete (or any other quick setting concrete) (1.5 – 2 bags per post) Galvanized Steel Pipe Bolts (3″ or 5″ – see below) Nuts Washers Plastic Hole Plugs (optional) Tools Power drill Drill bits Hole Saw Router Router bits Spade Level Tape Measure Socket Set String (optional) Push Tacks (optional) Design & Plan Your Homemade Pull Up Bar Rig This first step is the most important out of the whole process. What exactly do you want to build? Do you want just the one bar or would you like several bars of multiple heights? Are you building just a pull up bar or should your rig include some dip bars too? What width do you want your bar(s) to be? What height do you want the bar(s) A standard run of the mill outdoor pull up bar is usually around 6′ 10″ high, using 10′ posts with 3′ in the ground with the posts set 4′ apart. If you want to progress to do muscle ups, it can be useful to have some lower bars too. These allow you to jump into the muscle up position during your early training and typically want to be around chest height. Here’s a few examples of typical designs to get you thinking. Draw out your design roughly on a piece of paper and mark down the sizes of the posts and bars. When ready use this design and the shopping list links above to get all the materials you need. All posts should have been pressure treated or they will rot very quickly. To easily work out the height of a bar you can just reach with arms extended, measure the distance from your elbow to middle knuckles then add to your height. Drill Holes in the Posts for the Pull Up Bar It’s much easier to drill the posts before you put them in the ground so do this now. You need a hole for the bar to go through your posts. Measure the required distance down from the top of the post then find the center of the post width ways and make a mark. For a standard pull up bar this will typically be 4″ from the top of the post, but at a minimum leave 2″ so you don’t weaken the post. Use a hole saw drill bit with a diameter just a little larger than the diameter of your pull up bar. Make sure to leave a minimum of a 2″ gap between the top of the post and pull up bar hole. Pressure Treated Posts Power drill Drill bits Hole Saw Drill Hole for Bolt to Secure Pull Up Bar Next you need to drill a bolt hole in the post. The purpose of this hole is to allow you to put a bolt through the post and pull up bar to secure the bar, preventing it from spinning or moving sideways. Roll your post over and mark out where you plan to drill a bolt hole. The bolt hole should be perpendicular to the pull up bar hole and should intersect it. To line up the holes measure the height from top of the post to center of the pull up bar hole then use the same distance to mark out center of the bolt hole. For this hole you can use a normal large drill bit, so long as you have one slightly thicker than your bolts. Use a drill  with a diameter just a little larger than the diameter of your bolts Pressure Treated Posts Power drill Drill bits Hole Saw Route Bolt Holes in Posts Below are two types of fixings you can use to fix the bolt, pull up bar and post frame together. You can use either method depending on your preference but in both fixing options you’ll want to use a router so you can counter sink the bolt head and possibly washer and nut. Bar Fixing Option 1 – Proud washer & nut This is the simplest of fixing methods. The bolt and washer will sit proud on one side of the post, while the bolt head will be counter sunk into the other side of the post. You will use a router to bore the countersink hole slightly larger than the depth and size for the bolt head, for it to sit flush in the post. Bar Fixing Option 2 – Hidden washer & nut This fixing option is a little more involved than option 1 but does give a really great concealed fixing that looks like a professional job. Use your router to bore out the size and depth of your plastic hole plugs following the bolt hole. Do this on both sides of the post. This will allow you to sink the bolt head and cover it with a plug on one side and the washer and nut and again cover with a plug on the other side of the post. Check your bolts, washers, nuts and tubing caps all fit nicely then remove them all for later. The router piece should be the same diameter as the hole plug and drill to the same depth as the plug. The bolt head, washer and nut should all be small enough to fit within the plug. When you finally come to do up the nuts and bolts you will need a socket rather than spanner as the nut and bolt will be below the edge of the post Router Router bits Bolts Plastic Hole Plugs Measure & Set Out Your Posts Now you’ve finished preparing your posts you can lay them out on the ground with the base just next to where you plan to sink them. Measure between the posts to get the right distance and line up the base of the posts, this shows you where you should dig.  Place a small rock on the ground at the base of each post as a marker. Tape Measure Dig Holes for Each of the Upright Posts Follow these steps for each of your post holes, finish one completely then move on to the next. You will find you get better and faster at digging these holes the more you do, the first will be the slowest. Using a spade mark out a square, 12″ wide around the location of your marker rock then move the rock out of the way Keeping your spade angled straight down, give it a good stamp down several inches, rock it back and forth then move onto the next side Once you’ve cut the 4 sides make 2 more cuts forming a cross in the middle – this makes it easier to separate and lift the dirt Put the spade in one side and rock back and forward to loosen all dirt in the hole Lift all loose soil with your hands….using your hands is really the easiest and quickest way, so long as you don’t mind getting them dirty
outdoor pull-up bar 1

Outdoor Pull-up Bar

Mark on the ground (5 ft apart) where you want the posts for your pull-up bar. Dig square holes 10 inch x 10 inch ensuring that the marks you made in the ground are in the middle of the holes. These holes should be about 3 ft deep for 10 ft posts or 3-4 ft deep for 11 ft posts. Use around 2-3 inches of gravel in the holes to help water drainage and prevent the wood rotting. More or less gravel should be added to make the post heights the same. Paint the posts with fence paint or wood preserver. Put posts in hole and get a couple of people to hold them. Make sure they are: In line with each other The same height Flat edges on both posts are parallel Straight (use a level) Pour one bag of dry Postcrete in each hole around posts and re-check the levels. (Following instructions) Add correct amount of water to the postcrete. Poke the mix with a broom handle or a rod to mix the water into the powder. Make sure you keep the posts Level and Aligned while postcrete dries, usually around 3-5 mins drying time. Mix concrete (following instructions on bag), fill hole and level off. (1-2 days setting time) Fix the bar Measure the exact distance in millimeters between the tops of the posts (where you want the bar). Get the Bar made at a local steel merchant / retailer / fabricator using the measurements. See “Bar Welds” section below for more information. Clean and paint the bar with red oxide. Hold the bar where you want it ensuring it’s level and mark holes for the drill points. Remove the bar and drill the marks 3 1/2 inch – 4 inch (same length as thread on the bolts. Use a 9 mm drill bit even though it’s a 10 mm bolt). Wind-in bolts and washers with spanner to fix bar in place and finish the pull-up station! Bar Mouting You essentially have two options – a welded bar mount, or DIY bar and cup mount. It’s far more preferable to have your pull-up bar made to measure and welded by a local steel fabrication company. The image to the right is an example of a welder bar mount. The spec of this bar is; 33 mm thick steel tube with 100 mm x 40 mm welded brackets on each end (2 x 10 mm holes on each bracket). The tube should be around 1.4 metres long including brackets, but measure this after the posts are installed! If using a local steel company is not an option you can go for the DIY route and use a bar and mounted cup socket but the welded option is better as the bar is fixed and cannot rotate with a more heavy duty build.

Outdoor Pull-up Bar

Outdoor Pull-up Bar
Outdoor Pull-up Bar
Outdoor Pull-up Bar
Outdoor Pull-up Bar
Outdoor Pull-up Bar

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