DIY Pulley System for Home Gyms: The Ultimate Step-by-Step Guide
DIY Pulley System for Home Gyms: Step-by-Step Guide
Introduction
Welcome back, gym enthusiasts! I’m Kyle, and this is Kaizen DIY Gym. In today’s article, I’ll show you how to make the best DIY pulley system. This isn’t just another quick tutorial; we’re diving deep into the topic.
We’ll cover:
- How to build a loading pin.
- The best cables and pulleys to use.
- Various ways to use your pulley system.
- Options for purchasing a pre-built pulley system if DIY isn’t your thing.
Let’s get started!
Materials and Tools Needed
⏬ Materials ⏬
- Best budget pulley for paracord
- Best pulley for climbing rope and polyester accessory cord
- Best pulley to use with vinyl coated cable
- Best budget pulley to use with vinyl coated cable
- 1/8" vinyl coated cable
- Military grade paracord
- Polyester accessory cord (better than paracord)
- 3/4 inch floor flange
- 3/4 inch pipe cap
- 3/8” eye bolt
- 3/4 inch pipe nipple, 12 inches long
- 1 1/4” PVC
- Carabiners
- 5/8” hitch pins
- 1” Hitch pin
- Soft loop tie-down straps
⏬ Tools ⏬
- Drill press or Cordless drill
- Dewalt sliding miter saw
- 3/8” drill bit
- Bolt cutters for vinyl-coated cable
Step 1: Build the Loading Pin
The loading pin holds the weights for your pulley system. Here’s what you’ll need:
- 3/4 inch floor flange
- 3/4 inch pipe cap
- 3/8” eye bolt
- 3/4 inch pipe nipple, 12 inches long
- 1 1/4” PVC
Instructions:
- Drill a 3/8” hole in the center of the pipe cap. Use a drill press for precision or a cordless drill if you don’t have one.
- Cut the PVC to about 11.5 inches. This prevents metal-on-metal contact.
- Assemble the eye bolt into the cap and tighten it with a nut. Add a lock nut for extra security.
- Screw the flange onto the pipe nipple, add the PVC, and finish with the cap.
Optional: Attach a small plywood base to protect your weight plates.
Step 2: Choose the Right Cable
The cable or cord is essential for a smooth experience. Here are my recommendations:
- 1/8" vinyl-coated cable: Classic, strong, and durable.
- Military grade paracord: Lightweight and easier to use.
- Polyester accessory cord: A premium alternative to paracord.
Pro Tip: Use bolt cutters for vinyl-coated cable or scissors for cord. Always singe the ends to prevent fraying.
Step 3: Select the Best Pulley
Here are my recommendations:
Step 4: Assembly
- Attach the loading pin to your cable or cord.
- Thread the cable through the pulley.
- Secure everything with carabiners and KDG