Introduction: Plyometric Box With 5 Different Heights!

About: Hobbyist, part time college teacher regarding industrial design topics.

I just love to run, specially trail running. Besides training
speed there is another very important factor, strength.

There are several different ways to get stronger legs but one I Iove is box jumping that is why I decided to build one for myself.

The design is different to other plyometric boxes, most of them have 3 heights. After several design sessions I came up with this alternative that has 5 different heights. The main constraint was to have one box from a single plywood sheet.

The different heights are 40, 50, 60, 70 and 80 cm. I decided to include the specific numbers using homemade laser cut stencils with military ranks, the higher the height, the higher the military rank.



1 plywood sheet (5/8, 3/4 or 15mm)

1-1/2 in wood screws

Wood glue


Table saw (or circular saw with a guide)

Jig saw

Wood router with a 1/8 Rounding Over Router Bit


2in forstner bit

1/8in steel/wood drill bit

Phillips screwdriver

Counersink tool


Laser cut stencils on regular print paper

Utility Knife

Spray Adhesive

Spray paint

Step 1: Design

There are 8 pieces for this box. I used 15 mm plywood:

A: 70x60 B: 77x57 C&D:77x68.5 E: 60x48.5 F: 57x41.5 G: 60x20 H: 60x37

Wait, what? 15 mm thickness plywood? Yes, that´s what I found with my wood supplier, but don't worry I am also adding a table with the modified dimensions if you have 5/8 or 3/4in material.

Step 2: (optional): Using Different Thickness

Use the table as a reference to make your cuts if you are using 5/8 or 3/4 plywood. The consideration is that the disk kerf is 0.094in.

Use the attached dwg file to see more details and use my number one shop rule, "Check the design three times, measure twice and cut once."

Step 3: Initial Cuts

Review the design and try to cut all the similar lenghts with the same table saw setup (or fence position) to minimize assembly issues.

Step 4: Assemble the Parts

Mark the screw locations on the borders every 4 inches. Use a small bit to have a pre-drilled guide for the screws and minimize the possibilities to split the plywood during assembly.

Use a countersink to prepare the holes so the screw heads are flush and the final surfaces are better for the final user.

Step 5: Add Handles

Using the forstner bit and the jig saw cut the handles to ease the jump box movement.

Step 6: Round the Edges

Having rounded edges is a must to protect your legs in case something goes wrong during training.

Remember to remove the screws before routing the edges to avoid bit to metal contact.

Step 7: Final Assembly

Add glue to the wood edges if you desire a stronger box

Step 8: Reinforce the Box

You can strengthen the box using the plywood sheet scrap installing some parts inside at the middle position between sides C and D. You just need to add glue and thats it.

I you prefer to go one step further, add some more wood at the corners, scrap or pallet sections are just great options.

Step 9: Decorate Your Box

I decided to include marks showing the jumping height figures. But, as part of the concept I included some generic military ranks.

I prepared home made stencils using a home laser engraver. You only need to apply some spray adhesive find the position and press against the plywood. Cut the small paper bridges with the utility knife if you like.

Just apply a light and fast paint layer.

Step 10: Use Your New Plyometric Box

You are ready to go!

The first level can't be used to jump but guess what? It can be used:

- as a step

- to perform triceps dips

- you can do assisted or elevated lunges

- bench push ups

- and a lot of other exercises.

Exercise Speed Challenge

Grand Prize in the
Exercise Speed Challenge