DIY Doorway Pull Up Bar Pieces Ninjaflex

thingiverse

I was really disappointed that doorway pull up bars were sold out everywhere due to Covid-19 / quarantine, so I decided to create my own. It costs $20 to make which is on par with similar bars on Amazon. I 3D modelled and printed some end caps for it using Ninjaflex so it doesn't scuff up my walls. 4/10 update: I added some parts that hold a 3/8" steel rod in the middle of the pull up bar so it isn't just relying on the screw coupler to hold the pieces together. The parts all friction fit together. Instructable: https://www.instructables.com/id/Doorway-Pull-Up-Bar-From-EMT-Conduit/ Disclaimer: I don't know how strong it is, and the weakest point is definitely the set screw coupling the two pieces together. If anyone has recommendations for making it stronger please let me know in the comments! I weigh 200 pounds and it seems to be holding me just fine. Steps to make Doorway Pull Up Bar You'll need some EMT conduit, 2 feet of 2x4 wood, and some screws and bolts Materials - 1" EMT Conduit - You only need around 60" of it (5 feet), but Lowes only sells it in 10ft sections. $11 - Lowes - 2 of Right Angle Elbow (1" EMT). $6.18 each, $12.36 total - Lowes - 2x4 wood - $3 - Home Depot - Screws and bolts Here's the order that I assembled things in: Right Angle Connectors to 2x4 1. Measure 18" apart on your 2x4 and mark the hole locations. You want two wood screws for each side, so make sure the right angle elbow is far enough up on the wood for that. 2. Clamp one of the right angle bars onto the wood on top of your marked holes as shown in the picture 3. Drill holes into the wood. First use a 11/64" drill bit in the EMT so the screw can pass through it without issue, then use a 1/8" bit in the 2x4 wood so that the wood screw gets a good grip. 4. Drill in the first screw. 5. Tilt the EMT until it's as close to 90° to the wood, then drill/screw in the second screw. 6. Repeat for the second right angle connector Set Screw Couplers Screw in the set screw connectors wherever you want, I angled them at 45° because I thought it looked cool and just in case I needed to screw into them (Didn't need to). Attach the 8.5" sections of EMT to each set screw If you wanted to make this part more secure, use some bolts and nuts for this part as well. I didn't feel like buying more bolts so I didn't. Horizontal bar - the main stuff 1. Hold up the assembly so far to your doorway and determine where the long conduit section needs to be attached. For my doorway with molding on both sides it needed to be right up against the set screw coupler, so I marked the spots there 2. Clamp and drill holes through the horizontal pipe and the right angle connector where it needs to be. I just used a single bolt to connect these, but it's a big bolt so I used a step drill bit to drill it to the right size. This part will depend on your setup, but use lots of clamps and hope for the best with alignment. 3. Drill the first hole, put a bolt through it, then mark where the second bolt hole needs to be on the two pipes. For alignment it might be easiest to drill a small hole through the two pipes while they're sitting on top of each other so it's perfectly aligned. Finishing Touches Print 2 each of the end caps on this page and slide them onto your pipe, they should fit snugly. If you're printing in normal TPU and not ninjaflex you might need to add some tolerance, but it also might just slide on without issue.