Creating your own exercise bench using timber is an excellent way to add a customized piece of equipment to your home gym. With a few materials and some basic woodworking skills, you can build a sturdy and functional exercise bench. Follow this step-by-step guide to build your own exercise bench using a 100x100x2400mm timber fence post, 150x22x2400mm wood planks, and flat joint plates for added strength.

Materials and Tools Needed (Check some of my tools here)

• 1 timber fence post (100x100x2400mm)
• 2 wood planks (150x22x2400mm)
• 6 flat joint plates
• Wood screws
• Wood glue (Optional)
• Sandpaper
• Measuring tape
• Saw (circular, miter or hand saw)
• Drill and drill bits
• Clamps (For glue)
• Upholstery foam (Optional for comfort)
• Vinyl or fabric (Optional for comfort)
• Staple gun and staples (Optional for comfort)

Step 1: Gather Your Materials and Tools

Ensure you have all the necessary materials and tools listed above. High-quality timber and wood planks will ensure durability and strength.

Step 2: Cut the Timber and Wood Planks

Measure and cut the timber fence post and wood planks according to the following dimensions:

• Bench Support: 2 pieces of 300mm each, 2 pieces of 250mm each, 1 piece of 1000mm, all  from the timber fence post
• Bench Top: 2 pieces, 1200mm long from the wood plank (You can add some left overs or other wood perpendicular to these ones for extra strength).

Step 3: Assemble the Bench Support

1. Put the 300mm piece on the floor and find the middle, add the 250mm piece and put it on top making sure you have 90 degrees angle on each side.
2. Do the same with the other 2 (300mm and 250mm).
3. Attach the flat joint plates on each side with wood screws for strength. (You can add glue).
4. Once that is complete, add the 1000mm piece on top of those 2 supports and make sure you have again 90 degree angles.
5. Attach on flat joint plate on each side with wood screws and you should have something like the image below.

Step 4: Secure the Top of the Bench

1. Here I would recommend to add at least 3 perpendicular boards with the total or almost total the width of the 2 wood planks (I added 4 for extra strength and balance).
2. Pay attention to where you put the screws as you will need to attach the 2 150mm wood planks on top.
3. Attach the 2 1200mm with the structure built before and you should have a very strong bench to start with.
4. Check for Stability: Ensure all joints and connections are secure. The frame should be stable and not wobble.

Step 5: Prepare the Bench Top (This is optional and if you don’t need comfort, you can end here).

1. Sand the Wood Plank: Sand the 1200mm wood planks to smooth out any rough spots and edges.
2. Cut the Foam: Cut the upholstery foam to the same dimensions as the bench top (1200mm x 300mm).
3. Attach the Foam: Place the foam on top of the bench and secure it with adhesive spray if desired.
4. Cover with Vinyl or Fabric: Lay the vinyl or fabric over the foam, ensuring it is centred and smooth. Pull the material tight and staple it to the underside of the bench top, starting from the centre and working your way to the edges. Ensure the material is taut and wrinkle-free.

Step 7: Final Touches

1. Sand and Finish: Sand any rough edges or surfaces on the frame. Apply a finish, such as paint or stain, if desired, to protect the wood and enhance its appearance.
2. Inspect for Stability: Check all connections and joints for stability. Make sure the bench is sturdy and can support your weight.

Step 8: Start Using Your Exercise Bench

Your DIY exercise bench is now ready to use! Incorporate it into your workout routine for bench presses, step-ups, and other exercises. Enjoy the satisfaction of using a bench you built yourself.

Safety Tips

• Ensure all screws and joints are securely tightened.
• Regularly inspect your bench for any signs of wear or damage.
• Use appropriate weights and exercise caution to avoid injury.

Building your own exercise bench with wood is a practical and rewarding project that enhances your home gym setup. With some basic materials and tools, you can create a durable and functional bench tailored to your fitness needs. Happy building!

If you have any questions or want to share your DIY exercise bench, send me a message and if I get a lot of requests, will add a video explaining the whole process.