DIY PowerMax AE Power Rack Clone

This is a shop-built, DIY power rack that's a little different than what you're probably used to seeing. It's modeled after the PowerMax AE Power Rack which features an open walk-through design.

I looked at numerous rack designs but settled on this one because of it's improved stability. Instead of a typical 4'x4' footprint, this rack is 6'x4'. That means it also takes up more space in your room, so keep this in mind.

Despite being larger, this rack uses about the same amount of lumber as other DIY racks due to it's minimalist design, which helps keep the cost reasonable.

All in, I spent about $250 on materials, including paint. With a few tweaks, this rack can be built for less than $200 - a huge savings given that the PowerMax AE sells for upwards of $3,000.

Link to Sketchup model: https://3dwarehouse.sketchup.com/mode...

Link to imgur gallery with detailed measurements and cut list: https://imgur.com/a/Q6Kgyiw

afterglow's channel with detailed step-by-step instructions on building your own version of this rack:    / @eligibleeconomist  

Construction Notes: I used standard 3/8-16 threaded bolts, nuts, and washers to complete this build, mostly 5" but a couple 4" and 6" as well. Uprights were connected to the base from underneath using countersunk 3/8 lag bolts and braced with the black plywood gussets. Rear angled braces were fastened to the rear uprights and crossmember using 3" deck screws. I used a 1-1/16" x 7" long auger bit to drill the holes for the rods. Safety rods and pull up bar are standard 1" black gas pipe with 2x 90-degree elbow connectors and 2x threaded end caps.

The only power tools I used on this whole build were a good cordless drill and a circular saw. Yes, those gussets were cut out using a circular saw. A scroll saw or jigsaw would've made that job a lot easier. I used a hand saw and chisel to shape the j-cup profiles, but you could make that job a lot quicker if you had a band saw. And clamps. Lots and lots of clamps.