Project: Olympic Flat Bench With Weight Set Page 1 of 33

Olympic Flat Bench

with weight set




NOTE: The measurements within this text and 2D documentation are given both in
millimeters and inches (in brackets). This website is based on ISO measurement unit system, which
is the international standard. I apologize to the people who use other measurement units; but I
believe that measurements given in millimeters and inches should be adequate for everyone who
would like to build this project.
Besides that, on todays Internet it is easy to purchase the ruler containing all the
measurement units and overcome the difficulties of any kind.

Use various tools and clamps in process of welding, so you could weld the items together with
accuracy.

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Subassembly List



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1. Flat Bench Subassembly Parts List and 2D Documentation




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Frame Components


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Standard Parts








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2. Weight Set Subassembly Parts List and 2D Documentation




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Assemblage Instruction
1. Flat Bench Subassembly

1. Weld the Cover 50x50mm (items 11) to the Square Tubing 50x50x4 Cut Lenght 400mm (item 7).





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2. Weld the Cover 50x50mm (items 11) to the Square Tubing 50x50x4 Cut Lenght 200mm (item 8).




Make the two of these subassemblies

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3. Weld the Square Tubing 50x50x4 Cut Lenght 1100mm (item 5) to the subassembly from the previous
picture.




Weld the Dumbbell Holder (item 10) on the other end of Square Tubing 50x50x4 Cut Lenght 1100mm
(item 5).



Make the two of these subassemblies



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4. Weld the Square Tubing 50x50x4 Cut Lenght 950mm (items 4) between two subassemblies made in
the previous step.









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5. Weld the Square Tubing 50x50x4 Cut Lenght 390,36mm (item 3) to the assembly made in step 1.



6. Weld the Square Tubing 50x50x4 Cut Lenght 190,42mm (item 2) to the assembly from the previous
picture. Chamfer the items edges on places where the items are joining together by welding.




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7. Weld the Square Tubing 50x50x4 Cut Lenght 1285,36mm (item 1) to the assembly from the
previous picture. Chamfer the items edges on places where the items are joining together by welding.






8. Weld the subassembly made in step 4 to the subassembly made in the previous step.



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9. Weld the Square Tubing 50x50x4 Cut Lenght 1370,00mm (item 6) to the subassembly from the
previous picture.







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10. Weld the Sheet Support (item 12) and Triangle Support (item 13) together.



Made six of these subassemblies

11. Weld these six subassemblies to the subassembly made in step 9.




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12. Fasten the Sheet (item 9) to the subassembly made in the previous step using standard parts: Slotted
Pan Head Screw M6x35mm (item 14), Spring Lock Washe A-6 (item 15) and Hexagon Nut M6 (item
16).







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2. Weight Set Subassembly

1. Weld the Delimiter (item 2) to the Round Tubing D31,8x6,3mm (item 1).





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2. Line up the dumbbells at the both ends of subassembly made in the previous step.





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3. Fix the dumbbells using Dumbbell Nut (items 5).





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