Diy olympic bar

Diy olympic bar DEFAULT

Space Saving DIY Barbell Rack / Bar Storage

My garage gym has only a single, three-bar gun rack, and I own more than three bars. I’ve been carefully leaning bars against the walls and even leaving some in an unused corner on the floor (rubber floors, don’t worry!) Since I like to keep my gym looking nice and clean, not having a place to put these bars was getting on my nerves, so I decided to make myself my own DIY barbell rack.

Updated January 2018 – just checking for any outdated info or dead links.

DIY Barbell Rack in the Garage Gyms' garage gym

Garage Gyms’ DIY Barbell Rack

If you have the wall space for a gun rack, I strongly suggest just buying one. It’s obviously much simpler than building your own DIY barbell rack. Like I said, I have one already but it only holds three bars (below). I can’t really upgrade mine to a six bar holder because of where it is installed, and I don’t have any other convenient places on my wall wide enough to put a second gun rack. I needed a different solution.

My current gun rack situation - no room for 6 bar holder

With my gun rack above my dumbbell rack, I’d never be able to reach bars any higher, so a 6-bar gun rack is out of the question. It’s already not great grabbing for that top bar, and I’m taller than you!

I also didn’t really want one of those 9-bar vertical bar storage boxes that most equipment dealers sell. I just don’t like the idea of dropping nice bars into those metal sleeves. Some brands have a lined sleeve, which is better, and that does help reduce damage to the bar, but I also didn’t want to commit any floor space to storing bars. I simply wanted the bars as out of the way as possible, and that’s why I went with this kind of DIY bar rack.

Full disclosure, this isn’t an entirely original idea. I saw a picture of a DIY barbell rack some time ago that was more-or-less the same kind of rack. Unfortunately I didn’t save that link or picture, but it didn’t seem overly complicated so I just winged it and it turned out great. The really cool thing about a rack like this is that it isn’t load bearing (the bars are resting on the ground) so it can be built to hold any amount of bars.

DIY Barbell Rack Hardware

I went with cabinet-grade pine because it looked nice and wasn’t overly expensive. It also comes in 3″ and 4″ wide pieces which was perfect for this. You can use any wood you want though since it’s not a load bearing rack. Also because it’s not load bearing, you can mount the rack to the wall using wood screws; you don’t need to go crazy with wedge anchors or giant lag screws or anything like that.

You’ll need one mending plate and two screws per PVC cup. Make sure that your mending plates are countersunk, and that you buy the proper flat head screws that will sit flush with the plate. The mending plate packaging suggested ¾” #6 screws, but I went with 1″ #6 for a more secure hold.

  • 1″ x 3″ x ?’ Select Pine Board ($6)
  • 1″ x 4″ x ?’ Select Pine Board ($10)
  • 2″ PVC Conduit ($5 for a 10′ piece)
  • 2″ Zinc Countersunk Mending Plates ($0.75 per plate)
  • #6 – 1″ Flat Head Philips Screws [2 screws per PVC holder] ($2 per 12 pack)
  • 3″ wood screws for mounting top portion of rack to the wall (I already had these on-hand)
Hardware for attaching the PVC cups to the board

A shot of one of my PVC cups, the 1″ #6 screws, and 2″ zinc countersunk mending plate.

Tools I Used

  • Drill (used various bits for pilot holes, and also a 1″ and 54 mm bit for base)
  • Powered handsaw (I used this to cut the PVC; not recommended!)
  • Jigsaw for cutting stall mat for base. Utility knife works too
  • Tape Measure
  • Level
  • Screwdriver
  • Electrical tape
  • Construction adhesive/Liquid Nails
  • Safety goggles!
  • Pen, marker, whatever

The Pipes and the Rack

I cut the 2″ PVC pipe into 2½” long pieces. That makes them as tall as the 3″ piece of pine (as a reminder, 1″ x 3″ board is actually ¾” x 2½”, which is why I cut the PVC to 2½”). I cut out the mouth of my first PVC piece by guessing how big I wanted the opening to be. I got lucky, it worked well; small enough that it held the bar, but wide enough that it doesn’t take three guys to pull it back out.

I used that first cut piece as the template for all of the others so that there was consistency. I also sanded down the pieces when I was done, and gave the mouth a rounded edge since the bar needs to slip in and out of this gap. I doubt PVC can scratch a bar, but why risk it; it only took 10 minutes to sand the whole lot of them.

My DIY Bar Rack cups, cut from PVC conduit in 2.5" strips

I used the same template for each piece so that they would all be uniform. I also took the rough edges off with some sandpaper after I cut them. I made more cups than I needed as back-ups.

I’m not sure I want to recommend cutting the pipe using the method I used, as I’m certain that it’s not the safest option out there (I used the electric handsaw for this – like a smaller sawsall.) If you have access to more/better tools than I do, cut it however you see fit. They are small pieces to cut with power tools, so whatever you do, be safe.

As you saw in the first picture, my bar holder can hold seven bars. Each cup is mounted 4″ apart which leaves a tad less than 2″ between each cup. I left extra space on both sides of the center holder because I knew that would be a permanent location for my Swiss Bar. You can place each holder closer, further, or whatever you choose. If you want to include space for specialty bars, I suggest laying them on the ground as if they were on the rack and then measuring the distances between the center of one bar to the next.

Let’s say you wanted to do a 6-bar holder; only for Olympic bars. Leave 3″ before you mark the board for your first holder. Then mark every 4″ until you’ve marked all six spots, add 3″ after the last mark then chop the rest of the board off. In this scenario, your board would be 26″ long.

Note: If you do have bars other than standard Olympic bars, or a mix of men’s and women’s bars, watch the length (or height, in this case) because they are not all the same. If you notice on my rack, I had to place the rack at a height that allowed for the cups to grab all of the bars, even the shorter Swiss Bar.

After you mark the board, figure out exactly where you’d actually hang it. You want to find at least two studs, and you want to make sure that those two studs aren’t lined up with any of your marks for the holders on the board. Once you found the spot and the height, level it, mark it, and drill pilot holes into the board and into the studs, but don’t actually hang it yet.

Attaching the PVC holders to the wood

After I found my marks for mounting, I taped each piece of pipe onto the board exactly where I wanted them using electrical tape. Electrical tape has some play that allows you to re-position easily, and removes easily.

Once I knew where the board was going to go on the wall, I numbered each PVC cup and then placed all the PVC cups onto the board using electrical tape. This allowed me to get each cup on straight and centered without drilling any holes. Once everything was to my liking, I placed and visually centered the mending plates into the cup (above image) and then drilled pilot holes through the tape, pipe, and board. I then took each cup off the board, then set them aside sitting in the same position as they would go back on the board.

If your pilot holes for the mounting screws wouldn’t be covered up by the cups, you could technically attach the cups before mounting to the wall if you wanted to. My mounting screws were going to be hidden behind the cups if I installed them first, so I needed to mount the board before putting on the cups. Either way, that’s pretty much it. Once you get the board up, drop in the mending plates and start threading the #6 screws into the pipe, and then screw each piece into the board placing each cup where you initially had it.

You should definitely hand-tighten these screws rather than power drilling them in. If you strip out these holes, you’ll not be pleased!

Close up of my DIY barbell rack

Closer look of the PVC cups once mounted to the board. Not that complicated really.

I was getting a very small amount of rattling when I slammed the garage door (this rack is mounted on the same wall), and I not only didn’t want to listen to that, but I also didn’t want the bars hitting that zinc plate. I added a 3″ strip of rubber foam weatherseal self-stick tape to the inside of each cup. The bars fit perfectly, and there is not even a hint of noise. I also no longer need to worry about scratching the bars on that mending plate. Easy!

Rubber foam weatherseal self-stick tape to prevent the bar from rattling

3″ strip of Rubber Foam Weatherseal self-sticking tape stops any rattling and risk of the bar scratching against the mending plate. Kind of ugly, but you can’t see it when the bar is in there anyway.

The Base

Base piece for the DIY barbell rack

The rubber-lined base plate of my DIY barbell rack.

This piece is pretty simple. It’s the exact same length as the top board, only it’s 4″ wide instead of 3″. There is exactly 1″ distance between the wall and where the actual bar sits in the top section of the rack, so I left exactly 1″ of distance between the wall and where the bar sits in the base. This way, the bar is standing straight up and down, and not leaning in any direction and putting any strain on the cups.

I used a 54 mm drill bit to put the holes in the base, and since this base board is the same length as the top board, all the marks went in the same place. Again, these holes are not centered along the width; they are exactly 1″ away from the edge of the board (the wall) which makes the holes closer to the front.

Since I didn’t want bars resting on concrete, I cut up a spare stall mat to be the same size as the board and attached it under the board. I used construction adhesive to hold the pieces together, and then for good measure I countersunk a couple of wood screws with 1/8″ – 1″ washers into the underside of the mat and into the wood. I used a 1″ drill bit on the mat for the countersinking.

You can attach the base either to the floor, or the wall. I just used liquid nails, but it can be anchored with concrete anchors, or nailed into the wall much like a baseboard. Your call. Do make sure you have the base centered with the top of the rack though, otherwise your bars will be leaning, and if you have OCD like me, you’ll see that every time you look at the rack.


My DIY guides probably leave much to be desired, and no doubt I’ve left something out. So my disclaimer… plan it out, think it through, wear safety goggles, and measure twice. This is a simple project, but if you don’t take your time, you’re bound to screw something up, and no one likes to start over. I still suggest a gun rack if you have the space for it though.

If you have any questions, leave it in the comments; I try to answer all comments that include questions. Good luck!


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Homemade Thick Bar

A Must Have Item For Your Home Gym!

Want better hand and forearm development? Train with thick handled barbells or dumbbells, or often referred to as Fat Bars. The thicker the bar, the less leverage the hands and fingers have while holding it. Training with thick bar equipment stresses out the hands and forearms big time!

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This book excerpt below explains the theory behind thick bar training. Read the article and at the bottom of the page I'll explain how to make a homemade thick bar barbell and dumbbell handles.

Dinosaur Training by Brooks Kubik

Book Excerpt

Lost Secrets of Strength & Development


Pages 89-92

Advanced dinosaurs train with thick handled barbells and dumbbells. A regular barbell or dumbbell is 1" or 1 1/16" in diameter. Dinosaurs use barbells and dumbbells that are 2", 2 ½" or even 3" in diameter. Why? Because using a thick handled bar is one of the very best things you can do to develop maximum muscular size and strength. The turn of the century strongmen-many of whom were enormously stronger than the vast majority of our modern "champions"-were well acquainted with the incredible effect of thick bar work. They thrived on it. The thick bar work allowed them to develop levels of upper body power virtually incomprehensible to those who train only with regular bars.

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Thick bars develop levels of muscular size and strength that cannot be duplicated with any other equipment. Thick bars are very difficult to control. Compared to an Olympic barbell, a bar with a 2" or 3" diameter seems like a log. Can you imagine bench pressing, pressing or curling a telephone pole? That's what it feels like when you use a thick handled barbell. You cannot rely on style, form, timing or technique to complete a lift. You have to do it with sheer strength. To paraphrase Dr. Ken Leistner, "all you can do is lie back and push" when you bench with a thick handled bar. That's one reason why thick bar work is so effective. It imposes a tremendous burden on the muscles, tendons and ligaments-a far, far greater burden than a regular bar imposes.

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A second reason why thick bar work is so beneficial is that the bar forces you to involve your forearms, hands, wrists and fingers to a far greater degree than does a conventional bar. This in turn causes a stronger mind-muscle link, which inevitably leads to greater gains in muscular size and strength. Have I lost you? Stay with me, I will explain everything.

What do I mean when I talk about a "mind-muscle link"? I mean the connection between your brain and your nervous system. Whenever you lift a weight, the lift begins with the brain consciously directing the muscles to push or pull in a particular direction. The message from the brain is carried to the muscles via the nervous system. When the muscles receive the message, they respond by pushing or pulling in the manner directed by the brain. That's the mind-muscle link: the connection between the brain, the nervous system and the muscles.

Messages from the brain to the muscles are transmitted by nerve impulses. The strength of each individual nerve impulse, the total number of nerve impulses, and the frequency with which nerve impulses are transmitted from brain to muscle is one of the most crucial factors in the amount of force you can exert in any given lift. I have no research studies to cite and no way to prove that my opinion is correct, but I firmly believe that using thick bars in your training causes an increase in the strength of individual nerve impulses, the total number of nerve impulses and the frequency of transmission of nerve impulses.

As I noted above, thick bars are terribly awkward and extremely difficult to handle. You have to adjust the bar's path constantly as you lift it or else you will get hopelessly out of the groove almost immediately. There has to be constant feedback between the brain and the muscles. I believe that the necessity of constant feedback causes a stronger mind-muscle link and I believe that this is one very important reason why thick bar work is so incredibly productive.


Thick bars are terrific for strengthening the forearms, wrists, thumbs and fingers. Any exercise you do with a thick bar automatically becomes a test of hand and finger strength. Pulling movements are almost impossible with a thick bar, curling movements are incredibly rugged and even pressing exercises are downright nasty when you do them with a thick bar. As a dinosaur, you will be doing plenty of specialized grip work, but be aware that you will work your grip savagely by simply using a thick bar instead of a regular bar for your upper body movements.


There is yet another important thing about thick bars. Wimps, yups and wannabe's won't go near them. Muscle pumpers and drug babies wouldn't touch a thick bar on a bet. The chrome and fern crowd would rather give up their Evian water and celery sticks than try to lift a thick handled bar. You may think I'm kidding but I'm deadly serious about this. Before I started training in the sanity of my basement gym, I took my 3" bar to the gym where I trained and I was always amused by the reaction.

Some guys literally ran away whenever they saw the thing. They were very obviously intimidated by the large, thick mass of iron. They always went over and found solace in the chrome plated dumbbells the gym owner had purchased from a women's spa that went out of business. The only guys who ever wanted to use the thing were Ted Solinger and Bruce Bullock, who later became my training partners in my home gym. In other words, the thick handled bar was a great way to tell who was serious about training and who was content to "sculpt" and "shape" and do meaningless movements with chrome-plated baby weights.

If I ever open a gym I will stock it with thick handled barbells and dumbbells. Doing so would be a great way to discourage the wimps and yups and talkers from joining the gym. One look at the thick handled bars and the twinkie crowd would run for cover. So would the muscle pumpers-they would immediately realize that lifting a bar like that required STRENGTH and pumpers as a group are about as strong as undernourished kittens. The only guys who would go to a gym that featured lots and lots of thick bars would be the kind of guys who were interested in strength, power and physical challenges. Come to think of it, the gym would cater to dinosaurs and nobody else. Not a bad idea!


Use thick bars for all of your upper body exercises. Always use a power rack for thick bar bench presses and set the bottom pins to catch the weight in case the bar slips. NEVER do thick bar benches outside the power rack!

Use your head when you begin to incorporate thick bar work. Drop the poundage at first. You will NOT be able to handle your regular poundage when you first begin thick bar movements. The first time I tried thick bar benches, all I could handle was 365 pounds-and it almost killed me. With a regular bar I was handling 405-410 at the time.

A three-inch bar is too thick for some lifters to curl. If the bar is too thick for you, your elbows will let you know! Be alert to this and do not hesitate to drop from a 3" to a 2" bar if your elbows protest.

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Ironmind sells a beautiful 2" bar sized for Olympic plates. It is called Apollon's Axle, after the great oldtime strongman, Apollon, who regularly lifted a 2" railroad axle as part of his strength show.

You can also make your own thick bar. Let's assume you have an old 7' Olympic bar. Simply wrap heavy tape around the inside of the bar, then slide a 5' length of heavy steel pipe over the bar, leaving room for the plates on each rotating sleeve. Of course, once you convert the bar you won't be able to change it back.

Another option is to buy several sizes of steel pipe and hire a welder to weld them together for you.

This all may sound like lots of work and unnecessary expense, but it's not. Buying or making a thick bar-or several of them-is one of the very best investments you can make. Thick bars are one of the KEYS to strength and power. Buy or make one, use it and learn for yourself one of the true secrets of strength and power.

Article by Brooks Kubik

Fat Bar Dumbbell Handles

1" pipe foam OD is 1 5/8"

1-1/2" PVC OD is 2" ID is 1-1/2"

Two Olympic dumbbell handles

Tennis racket grip tape, or hockey stick tape

Electrical tape

Homemade fat bar dumbbells

Cut the PVC 4-3/4" long. Measure the distance between the rotating ends of your Olympic dumbbell handles and cut the PVC 1/8" less than the measurement. This will allow the ends to rotate after you install the thick handle.

Cut the pipe foam to size and remove the protective covering for the adhesive and stick the foam around the handle.

Homemade fat bar dumbbells

Wrap the PVC with the tennis racket grip tape and secure each end with electrical tape. Squeeze the PVC over the foam. Replace the rotating sleeve.

Homemade fat bar dumbbells

Homemade Thick Barbell

1-1/2" x 6' galvanized pipe

Existing collars from a dumbbell handle and olympic bar

Hockey stick tape

Homemade thick handled barbell

1-1/2" galvanized pipe OD is 1 7/8"; your typical olympic weight center hole is 1-15/16". This leaves a clearance of about 5/16", which is OK because it allows the olympic weight to spin (don't tighten the collars right up against the plate) when you are doing a curling movement, just like a rotating end of a standard Olympic bar. What I don't show in the photo is the hockey stick tape. Adding the tape will increase the thickness of the pipe to about 2", and help me grip it as well.

Homemade thick handled barbell

I only bought a six foot length of galvanized pipe because I might use the pipe to sleeve an old seven foot olympic bar if I can find a cheap, good used one on craigslist. Then, all I have to do is cut my six foot pipe down to fit between the rotating ends of the used olympic bar. One inch pipe foam will keep the galvanized pipe from moving around on the olympic bar.

If you do sleeve an olympic bar, you'll get the added benefit of rotating ends, which puts much less pressure on the wrists when doing Power cleans etc.

Thick Handles for the Powertec Workbench Leverage Gym

1" pipe foam OD is 1-5/8"

1-1/2" PVC OD is 2" ID is 1-1/2"

Hockey stick tape

thick handles powertec workbench

Cut the PVC 5" long. Cut the pipe foam to size and do not remove the protective covering for the adhesive (this will allow for removal) and place the foam around the handle. Wrap the PVC with the hockey stick tape. Squeeze the PVC over the foam. This will be a snug fit!

thick handles powertec workbench
thick handles powertec workbench
thick handles powertec workbench


Get ready to build strong hands and forearms! Also, as the article stated above "You will NOT be able to handle your regular poundage when you first begin thick bar movements." Train regularly with a thick bar and you'll be way ahead of the lifters who don't.

Keep liftin'

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DIY Beast Mode Gear: How to Build Your Own Barbell

There have been plenty of challenges living for the past six years as an American in Japan. First of all, finding shoes my size is a challenge at best and damn near impossible at worst. Finding t-shirts that don’t choke me while not simultaneously being covered in non-sensical (or at least grammatically incorrect) English is another. And let’s not even get into trying to find a decent steak.


But I digress, this article is about do-it-yourself (DIY) beast mode gear. Almost a year ago, I started my own gym in my town, and am the proud owner of one of the few Olympic-style weight sets in the entire town (including the three largest commercial gyms).



When shopping, however, prices reared their ugly heads. Weight sets that would have cost about 600 dollars in the United States were running 100,000 yen here in Japan (about a thousand American dollars) - before shipping! I spent the most I could afford and got the best set I could. Hey, heavy lifters are rare in Japan, and even more rare in the countryside. Almost everything has to be imported, and prices are at a premium.


Fast forward to last month, and I was working my squats. I was very happy to hit a personal best (post ACL surgery) of 210 kilograms (about 463 pounds) when I noticed that my bar, while not failing, had what I would call an excessive amount of “flex” in it.


Since this was my one and only bar for the gym, tearing the damn thing in half would not be a good idea. So, I went back into my documentation on the weight set and checked my bar capacity.


Open up to the proper page, and read “Recommended Max Weight: 200 kilograms.” Ooooops. Now, what do I do? I want to go even heavier, but if I do, I might just shear off the ends of my bar. Time to buy a new bar it seemed.


Here, prices reared their ugly heads yet again. When I checked prices for a high capacity bar, the cheapest I could find was over 50,000 yen (500 USD). A good quality bar like an Ivanko bar was going to run over 100,000 yen (1000 USD).


To be quite honest, I just couldn’t afford the damned things. So, as a former military officer who did his fair share of “MSU Ops” (Making Sh** Up Operations), I decided to DIY my new bar.



DIY barbell, build your own barbell, do it yourself barbell, building a barbell


The most important part, of course, is the heart of the bar, the core bar itself. After reading a series of highly informative (and quite often funny) articles by Dr. Ken Leistner (no stranger to the DIY iron game himself), I knew I wanted to get cold rolled steel. In stepped the helpful folks at Osaka Stainless Steel Company in Osaka, Japan.


Working with their representatives, we decided eventually on a 38mm diameter cold rolled hardened steel bar at 250cm in length (about 8 feet, so longer than your normal bar - it's the one on top in the photo). And it was really a good price too, only about a hundred U.S. dollars, including delivery.


I went with the bigger diameter bar (38mm as opposed to the standard 28mm bar) for a few reasons. First off, while I knew the bar I was getting was cold-rolled, that was no guarantee it was as strong as the steel used in a high-quality commercial bar.




Those extra millimeters of steel could be useful. Second, the extra diameter could also be useful as a grip aid. While not a true fat bar in the 2-inch or higher category, let’s face it, that extra almost half-inch is still going to challenge the grip on deadlifts and other pulls.


DIY barbell, build your own barbell, do it yourself barbell, building a barbell


So, I had my “heart,” now I needed the finishing touches. A quick trip to a local hardware store got me the pipes to go over the ends of my bar, a set of 50cm long 1.5in diameter water pipes.


With an inner diameter of 39mm and an outer diameter of 49mm, I couldn’t ask for a better fit if I had custom ordered the damn things.



Since this bar is meant for the power lifts and not Olympic lifts, I didn’t need bushings or bearings or anything else like that, I could affix the pipes to the bar directly with no rotation needed.


Using a series of high strength epoxies, I was able to fasten the pipes to the ends of the bar with no issues at all (while I would have loved to have welded them on, I have neither the skill nor the access to a welding set). Using an old set of screw-on collars to work as my inner collars and TA-DA! The BEAST is unleashed!


DIY barbell, build your own barbell, do it yourself barbell, building a barbell


I can tell you, so far this thing is a rock on my back. Taking it out on squats was like having a dead straight laser line across my shoulders, even when fully loaded, and even when I tried to bounce the top of a few squats just to see if I could get the bar to flex at all. As an added bonus, the extra bar width even felt a bit more comfortable on my shoulders, dispersing the weight a bit wider on the back muscles.


So, don’t despair if you are in a similar situation. While I doubt few readers of this are going to find themselves in a non-English speaking foreign country that doesn’t have a large heavy lifting community, you might find yourself in a situation where your finances don’t quite match the prices of commercially available equipment, or shipping and other costs make do-it-yourself work useful and worthwhile.


If you do decide to take the DIY plunge, here are a few tips I would share with you:


  1. Shop around. I checked over a dozen different sources (online and via telephone) before I settled on the bar that I purchased.
  2. Research. Check the dimensions, thickness, and any other information you can on the commercially available products you are trying to emulate or template off of. Even if your build is unique due to your circumstances, find out as much info as you can.
  3. Overbuild. Unless you are a master metalworker or fabricator, or you know someone who is, your welds and materials may not be as fool-proof as the commercial stuff. Let’s face it, York, Ivanko, and the rest have stayed in business doing what they do because they build good stuff and they know how to put it together. You’re not that good (yet?). So, overbuild if you can. If the commercial-grade rack you want has box walls 2mm thick, get something 3mm thick if you can. If you need something that can handle 500 pounds, build something that can handle 750 pounds. It might be a bit more expensive (hey, I could have built the BEAST for about three-quarters of the price I did if I had copied commercial measurements exactly) but the extra safety factor helps me sleep better at night.
  4. Try it out. Put the thing through its paces, but do it slowly. Just because you might want to build something that can take up to 1000 pounds, don’t just slap 1000 pounds on the thing first time out. Take it up slowly, and see what it can do.


In any case, I hope this encourages you as well to try and do your own home made beast mode gear for your own needs.

Topic: Fitness

See more about: barbell, gym equipment, DIY, weightlifting, equipment, training tools, home gym, at-home exercise, at-home workouts


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Now discussing:

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