Step 1: Price, Secondary Materials, and Primary Materials
Here's the breakdown of what you will need...
Secondary Materials (not a part of final construction)
3. Towel/Clean Cloth
4. Pipe Wrench
1. One - 2" Galvanized Tee ($7.84)
2. One - 2"/0.5" Galvanized Hex Bushing ($3.90)
3. One - 0.5" Galvanized Floor Flange ($3.56)
4. One - 5" x 0.5" Galvanized Nipple/Pipe ($1.13)
5. One - Container of 5min Epoxy Adhesive ($2.97)
Another note...the picture below has a (12" x 0.5") pipe. I was using a longer pipe in order to stack a greater amount of weight. I would suggest the 5" pipe if you intend on using the weight converter for deadlifting. Anything longer will exceed the height of your 45lb weights as it rests on the ground/on the bar.
Step 2: Cleaning
3. Towel/Clean Cloth
The purpose of this process is to make sure that the pipe threads engage each other correctly and smoothly. The step that follows this one will involve putting epoxy on some of the threaded areas, so it is important to make sure that extra elements do not impede the pipe connection process (in the form of dirt, grease, etc).
1. Spray all threaded areas with WD-40
2. Brush with Toothbrush
3. Wipe excess with Towel (wipe very well)
4. Check to see if the threads are clean (repeat process if not)
Step 3: Practice Your Assembly
1. Pipe Wrench
2. Galvanized Tee
3. Pipe Nipple
4. Floor Flange
...because epoxy only sets once.
You are going to want to make sure that the process is well rehearsed (unless you want to make another trip to Home Depot).
1. Lightly screw the [2" bushing] into the [2" tee]---(see picture #1).
2. Adjust the pipe wrench so that it will be ready to firmly adjoin the two pieces (but don't do it until the epoxy is ready)---(see picture #2).
3. Lightly screw one end of the [5" x 0.5" pipe nipple/pipe] into the floor flange---(see picture #3).
Step 4: Mixing Epoxy and Final Assembly
2. All materials from step 3.
1. Following the manufacturer's directions, mix about 2 tablespoons of epoxy onto a disposable surface (newspaper, paper plate, etc)
2. Quickly mix the epoxy using the plastic mixing stick that comes with the epoxy container.
3. Repeat everything from step 3, but make sure to apply a liberal amount of epoxy to the threads before tightening. In addition, make sure to tighten the pieces as much as humanly possible.
4. Let the epoxy set for at least an hour (24 hours is best though).
Step 5: Racking Up Those Weights
1. One-inch (inside diameter) weights.
2. What you just made.
1. Connect the remaining end of the [0.5" pipe nipple] to the [0.5" bushing]---(see picture #1). You should not use epoxy on this connection. This is what makes it adjustable.
2. Remove the connection, place the flange on the floor, and put a few weights on---(see picture #2).
3. Reconnect the top connection (pic #3) and mount onto your olympic bar (pic #4).