Introduction: Hangboard With Pull-up Bar
This Hangboard is easy and cheap to make if you have the right tools.
It can be used to strenghten your fingers, hands, arms and upper body.
It is also quite compact and you can install it anywhere.
-A piece of wood, preferably hardwood, I used a piece of 20cm by 60cm beech wood.
- flat iron for the brackets, I used about 400 mm by 50 mm with a thickness of 10mm.
-steel tube/pipe for the bar, I used 900 mm long one inch diameter tube (25.4mm).
- sander / sandpaper
-welder (tig, mig/mag or stick will do)
Step 1: Designing the Hangboard
Once you have chosen a piece of wood you can use, start drawing on it wih a pencil roughly where everything will go, you can do that to avoid any mistakes once you start the CAD.
When you are done with you can open Fusion 360 and start drawing the rough shape.
Once it's done you can start drawing the grooves, to do that you can draw two circles and join them with a line as seen on the image above.
when all the grooves are drawn and you have checked that you have enough space left for mounting holes and the brackets for the pull-up bar, you can cut the grooves and place the locations for mounting holes and brackets.
the last step of the design process is to choose the radius of the chanfers and to make shure they fit with a decent amount of space between each groove.
Step 2: Drawing and Cutting the Grooves
with the help of your cad design you can start drawing all the locations of grooves by using the center of the two holes you used to make the groove.
You can then drill the holes usign the same diameter drill as the heigt of the grooves.
Once all the holes are made, clamp the board on your work table and, using the jigsaw, join the holes of each groove as shown in the image above.
Step 3: Cutting the Shape
with the grooves cut, you can draw the shape of the board and cut it with the jigsaw.
After that you can use a wood rasp to get closer to the required dimensions, both in the grooves and on the overall shape of the board.
Step 4: Finishing the Hangboard
with the shape and the grooves done, you can now round the edges of all the grooves using a handheld router, try a few different radii and see how they feel on your fingers, bee careful not to take to big of a radius otherwise you wont be able to hold in the groove.
Don't foget to chanfer the exterior edge of the board.
Step 5: Designing the Pull-up Bar and Its Brackets
Just like the hangboard designing the pull-up bar is a crucial step of the process.
Try measuring the clearence you need between the wall and the bar when doing a pullup, this will determine the length of the bracket, i used about 60mm from the wall.
you can find a part of the bracket on the file above wich can be printed and glued on your piece of steel to cut it out with an angle grinder.
Step 6: Cutting and Drilling the Brackets
I recommend tacking the two pieces of steel together, that way you only have to cut once, but be careful it is very easy to accidentally cut on an angle when grinding through 20 mm of steel.
I used two plates of 50 by 80mm for the mounting plates with four holes for 30mm long screws.
When cut, chanfer the plates and the brackets with a flap wheel on your angle grinder, make shure there are no burrs or sharp edges.
once they are cut in the right shape and safe to handle drill the holes fot the mounting screws, and I also recommend chanfering the holes so that the screws dont stick out
Step 7: Welding the Brackets
weld the brackets on the mounting plates, I used a tig welder but you can use whetever welding method you are most confortable with.
and you can finish this step by welding the bar on the bracket.
Step 8: Mounting Holes
after determining where you want to place your mounting holes you can drill them.
be careful, make shure the bar or the mounting holes aren't in the way when screwing it to the wall.
I opted for three mounting holes and i used 100 mm long M8 wood bolts, and to avoid them sticking out i drilled a bigger hole using a forstner bit wiich has the depth of the height of the bolt head + a spacer.
Step 9: Almost Done
you can now sand the hangboard and paint the bar if you want to, I decided against painting beacause i think it looks good.
you can finally install the board, usnig a ladder choose the right height for you and then mark it on the wall.
Ask someones help to hold it while you bolt it down.
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