DIY: Reinforcing the Bench

In an earlier post, I showed you how to reupholster a bench. That method is great for taking a structurally sound bench, and dressing it up or making it into your own personalized piece of equipment. If you happen to have a bench that is not structurally sound, this post should help sort that out.

My first bench began its life as a typical adjustable bench press unit. As is typical with these types of benches, the uprights were in the wrong location for a guy my size. I used an angle grinder to quickly remedy that (I chopped them off). I dealt, similarly, with the upholstered portion of the bench.  What I had left was a solid frame with no actual bench and no more ill-spaced uprights.

Flat Bench, Version 1

Flat Bench, Version 1

My next step was to add back a flat bench. For this first iteration, I went with a couple pieces of 1/2″ angle iron screwed to a 1″x8″ board. I then added some carpet padding and wrapped it in a durable fabric. I rarely do incline or decline pressing, instead opting for overhead pressing and dips, so this worked well for a while as a basic flat bench. My bench press has increased steadily over the past few years to the point where I was no longer comfortable on this bench.

The basic structure was still adequate, but the angle iron and 1×8 board weren’t going to cut it any longer. On heavy attempts, I could feel the bench sagging under the weight and the narrow base left me feeling a bit unstable. I decided to upgrade to 1″ square steel tubing and a 2×12.

Square Steel Tube Frame

Square Steel Tube Frame

First, I drilled holes in the steel tubing so it would mount to the rest of the frame. Second, I added holes for bolting the steel to the wood. I then used the drilled steel to stencil the bolt pattern onto the 2×12. I drilled through the 2×12, and added T-nuts on the upper side of the board. From there, it was as simple as sliding the bolts through the steel tubing and the wood, and tightening them into the T-nuts.

Tee Nuts

Tee Nuts

I topped it all off with four layers of carpet padding, and wrapped it in the same durable orange fabric as before. The result is a much sturdier piece of equipment that I doubt I’ll ever out-grow.

Bench with Carpet PaddingBench with Carpet Padding

Bench with Carpet Padding

And here’s the finished product.

The Reinforced Bench

The Reinforced Bench

Got a bench that’s not keeping up with your training? Give this a shot and let us know how it turns out in the comments or over on the Facebook page!

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3 thoughts on “DIY: Reinforcing the Bench

  1. Pingback: Get a Grip: DIY Drip Tools | Garage Gym Guy

  2. Pingback: Get a Grip: DIY Grip Tools | Garage Gym Guy

  3. Pingback: Refurbish AB Hyper Bench | Garage Gym Guy

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