Would you like to do more exercise at home? No problem – with our DIY weight bench, plus wooden weights, you will be able to simply do your muscle training at home in your living room. And the best thing about your new piece of exercise equipment is that it won’t take up any extra space in your flat, because it transforms into a stylish coffee table when you turn it 180 degrees. We’ll show you how you can build your very own clever piece of furniture made from high-quality wood at home.
What you need
- Wood glue
- face mask
- ear protectors
- protective goggles
- Carpet knife/cutter
- screw clamps
- disposable gloves
- Protective gloves
- Birch plywood board (18 mm thick): 2x 1,314 x 414 mm, 2x 414 x 350 mm, 1x 1,350 x 350 mm, 1x 712 x 350 mm, 2x 100 x 350 mm
- Veneer panel (6 mm): 1x 570 x 300 mm, 1x 675 x 300 mm
- Wooden boards (18 mm): 6x 200 x 230 mm
- Wooden bar, diameter: 30 mm
- Wooden dowels (8 mm)
- Wood stain
- Foam material
- Spray adhesive
- Hook-and-loop fasteners (40 mm in width)
Let's start - step by step
Mark the positions of the holes
What you need: Protractor, Pencil, 2x wooden boards (1,314 x 414 mm), diagram
You will need two large wooden panels measuring 1,314 x 414 mm for the side panels of your weight bench. Saw these to length yourself or go to your local DIY store and have them sawn to the appropriate size.
You will work on one of the two boards to start. You will need to mark some measurements for the blind holes.
Drill the blind holes
As you can see from the diagram, you will need to drill different-sized holes in the wooden board. Use a 20 mm Forstner drill bit for the two small holes and use a 40 mm drill bit for the remaining larger holes.
We recommend using a bench drill to do so. This will prevent tears and dust. However, make sure to properly secure the board and place a piece of scrap wood under it so that you don’t drill into your work surface.
Sawing out the shape
You should sketch out your cutting lines before beginning to saw. Simply connect the outer edges of the drilled holes using a pencil and a wooden strip. Check the diagram again to see if all lines have been drawn in correctly.
Now you can use the holes as a starting point and saw out the drawn-out shapes using a jigsaw.
Sand the side panels
After sawing the wooden board, you will be left with the finished shape of the side panel. Now sand down the edges. If you use an 18 V multi-sander to do so, you can stick to the 18 V product range and use one rechargeable battery for several different tools, as you used the 18 V jigsaw in the third step.
Of course, your weight bench will also have a second, identical side panel. Follow steps 1 to 4 with another 1,314 x 414 mm wooden board to make the second side panel.
Mitre-cut the boards for the weight bench cladding
What you need: hand-held circular saw, Ruler, Pencil, screw clamps, ear protectors, protective goggles, seven wooden boards, diagram
You will now need seven more boards to clad your weight bench.
All edges must be mitre-cut so that they fit together perfectly. If you have never done this before, you can find all the most important information on mitre cuts and the corresponding settings for your saw .
Now saw all of the boards according to the measurements given. Make sure that they are clamped securely and that you take sufficient safety precautions to protect yourself.
If your hand-held circular saw is also part of the 18 V product range, you will only need to quickly exchange the rechargeable battery and can immediately continue with your project. It might be a good idea to charge the rechargeable battery for a short time after sawing. Then it will always be ready for use in other devices needed in the next few steps.
When you have finished, check whether the sawn-out corners match up.
Connect the bottom panel and side panel
What you need: screw clamps, Pencil, Wood glue
Have you managed to saw all the boards?
Then it’s time to work on the large bottom panel and one of the side panels from step 4. Place the bottom panel on your work surface and place one of the boards for cladding the weight bench in a vertical position on the shorter side of the board. Mark the width of the board on the bottom panel.
Now put the board for cladding the weight bench aside and glue the underside of the side panel. Then, position it vertically on the bottom panel, flush with the long side and with the correct distance to the shorter side, which you marked earlier.
Now hold everything in place using G-clamps.
Mark and drill holes on the side panel
Now turn over the bottom panel with the side panel attached and place it on your work surface.
Mark the drill holes for the dowels to attach the side panel: Draw in the first marking 5 cm from the panel edge – draw in the rest at a distance of 25 cm.
Then drill each hole into the side panel.
Insert the dowels
Apply glue to the drilled dowel holes and insert the wooden dowels with the aid of a hammer.
Depending on the depth of the drill hole, the dowel should be countersunk by up to three-quarters. Ensure that the dowels fit into the side panels and simply saw off any protruding ends.
Assemble the second side panel
What you need: all the tools, aids and materials you used in steps 6 to 8
Now assemble the second side panel (making sure it is the right way around) on the bottom panel. To do so, repeat steps 6 to 8.
Attach the boards for cladding the weight bench
What you need: boards to clad the weight bench, all tools and aids you used in steps 6 to 8
The basic structure of your weight bench is now complete. All that’s missing is the cladding.
Now it’s time to connect all these boards to the side panels piece by piece. Follow steps 6 to 8 to do so: Glue the board, clamp it securely, drill the holes, insert the dowels and cut the ends off.
Sand and stain the piece of furniture
What you need: Cordless multi-sander, G 80 grit sandpaper for the multi-sander, G240 sandpaper for the multi-sander, screw clamps, protective goggles, ear protectors, Protective gloves, disposable gloves, face mask, cloth, wood stain
Have you completely covered the bench in cladding and sawn off the protruding dowels? Great!
In this next step you will need to pick up your sander once more and completely sand the bench all over. G80 sanding paper is perfect for the first coarse sand. Take special care to ensure that all the dowel ends are sanded down.
Then, dampen your bench with a wet cloth. This will make the wood fibres stand on end. When you go over it again with fine sanding paper, your bench will be lovely and smooth.
Would you like to give your weight bench a high-quality, dark mahogany look? Then you will need to stain your new piece of furniture.
Put some wood stain on a cloth and rub it evenly across your weight bench. The more stain you use, the darker the bench will be.
Making the seat and rest cushions
What you need: cordless tacker, Carpet knife/cutter, disposable gloves, face mask, two veneer panels (6 mm thick): 570 x 300 mm and 675 x 300 mm, foam material, leather, spray adhesive
Now all that’s missing from your weight bench are the seat and rest cushions.
First of all, you will need two boards in the correct measurements. Saw them yourself or get ones in the right size at your local DIY store.
Now place one of the sawn boards on a large piece of foam material and cut along the edges using a cutter.
Attach the foam material to the wooden board using spray adhesive.
Then, cut out a large piece of leather and place it on the wooden panel with the foam material glued onto it. Fold the ends of the leather around the edges of the board and attach them using glue and a tacker.
Repeat these steps for the second back cushion.
Trim the leather on the corners to prevent it from overlapping.
Cutting the hook-and-loop fasteners
What you need: Carpet knife/cutter, hook-and-loop fasteners
You can attach the back cushions to your bench using self-adhesive hook-and-loop fasteners. You can get this material in a roll from your local DIY store.
Measure the length and width of your back cushions and cut a total of eight matching strips of this material from the roll. Then, attach glue to the undersides of both your cushions.
Attaching the seat and rest cushions
What you need: patience, concentration, finesse
Now place the back cushions on the bench.
Leave the hook-and-loop fasteners closed when they are glued to the seat/back cushions initially to ensure that they will fit together perfectly later on. Remove the adhesive strips and press the cushion onto the correct position on the wooden bench.
Well done! Your weight bench is now ready to use. If you would like to train your body weight (or simply need a new coffee table) then you can use your new piece of furniture right away.
However, if you would like to build a pair of cool DIY wooden dumbbells, then simply follow the steps below:
Saw out wooden hexagons
Of course, you will need two dumbbells if you want to have a good workout. As these will be identical, we’ll just show you how to make one. Repeat the following steps for the second dumbbell.
First, you will need six wooden panels (at least 200 x 230 mm) for one dumbbell.
Print out this template in the original measurements and place it on the wooden board. Transfer the shape using a pencil and saw along the lines you have drawn.
Repeat these steps for all six panels.
Glue the hexagons
What you need: Wood glue, screw clamps
Now build two weights using the six hexagons.
To do so, glue three of the wooden panels together, and repeat this process with the remaining panels to make the second weight.
Secure both structures from all sides using G-clamps and allow them to dry.
Assemble the G-clamps so that the wooden panels are pressed together from above and below, as well as from both sides. If you only secure them from above and below, they will shift apart.
Measure and saw the bar
A simple wooden bar can be used for the dumbbell handles. Measure 264 mm for the correct length and saw the bar. Make sure to clamp the bar properly.
Drill the holes
Now draw a centre point on each weight.
Drill a hole in the centre of each glued board using a Forstner bit. Please note: Only drill the two upper boards. Set your drill accordingly or put a mark on the drill bit. Use 36 mm as your guiding value.
Both wooden weights now have to be fully sanded all over.
It is a good idea to use an 18 V sander. Then you can simply reuse the rechargeable battery from the drill, multifunction tool or saw.
Gluing the dumbbell elements together
What you need: Wood glue
Now glue both weights to the bar.
Apply wood stain
What you need: disposable gloves, cloth, wood stain
If you would like your dumbbells to have the same dark mahogany look as your weight bench, then you will have to follow the steps outlined above to stain the wood.
We understand if you’d prefer to put your dumbbells to the side and transform your weight bench into a coffee table after completing this major project. But now you’re all set for your next workout! It’s time to get fit!
Bosch does not accept any responsibility for the instructions stored here. Bosch would also like to point out that you follow these instructions at your own risk. For your own safety, please take all the necessary precautions.