We have a couple of new pieces of fitness equipment that have been added to our home gym! So far Roger has built a pull-up bar, a heavy duty squat rack and now he can add plyo boxes to the list!
We’ve been mixing in CrossFit or CrossFit-inspired workouts here and there and noticed that they use plyo boxes a lot. Roger wanted to start incorporating the jumps so we started shopping around for plyo boxes. That was not fun. We didn’t realize they were so expensive! And on top of that, we wanted two. We were seeing 18-inch boxes for $100+ and 24-inch boxes for $129+ which didn’t sit very well for us.
We put our thinking caps on and Roger started thinking he could probably just build a couple. I think if he could build a gym-quality squat rack he could put a few pieces of wood together to make a box! And that’s just what he did and they turned out GREAT!
I’m going to do my best here to describe the process and hopefully the pics will help a bit too. They didn’t take too long to make, were very inexpensive and are super durable.
For the 18-inch box
- 1 – 8′ x 4′ sheet 3/4″ plywood
- 2″ screws
- wood glue
- paint (optional)
- anti-skid paint additive (optional)
- permanent marker (optional)
- circular saw
- stain brush
- paint brush or roller (optional)
- sanding block
- tape measure
- stencils (optional)
Measure and cut plywood. You’ll need four identical pieces for each side of the box. The sides are wider at the bottom than the top to provide a stable platform. Roger measured the total height and width he needed to make all four pieces and made one long cut. Next, he measured out the four sides and cut them out individually using each cut as a guide for the next piece. He was able to make both of our boxes from one piece of 8′ x 4′ plywood.
For each of the four sides:
- Total height measures 17.25″ (need to leave room for the 3/4″ thick top to make it a total of 18 inches in height)
- Measures 17.5″ wide at very top
- Measures 20.5″ wide at very bottom
- *Adjust measurements to make it your desired height
Cut 10-degree angles into the top and bottom of each box piece. This part was a little tricky, but necessary.
Here’s a better illustration of what I’m talking about in this step. A big thanks to this guy for helping us figure out how to do this part! Here’s another great tutorial I found on the CrossFit site.
Begin assembly. To ensure durability, he first used wood glue to glue all of the pieces together. Then, he screwed each of the sides together. It’s not coming apart! (You can see the wood glue start to run as he screws – if that happens, be sure to wipe it off right away before it dries.)
Make & assemble the top. To do this, Roger let the box dry and set for a bit and then he flipped it upside down onto a piece of plywood and traced around the top perimeter of the box. This gave him the exact size he needed to be sure the top covered the box and all sides completely. Super easy and worked like a charm. Glue and screw to the top of the box.
Drill 2-inch holes into two sides that are opposite from each other. These are handy for being able to carry and move the plyo box around more easily. Rog just used a 2-inch circular “mechanism” (lol!) that he attached to the drill.
Sand and stain. I didn’t spend too much time sanding because it was already pretty smooth. Then I applied one coat of stain and let it dry completely.
*The rest of these steps are completely optional. We just wanted to personalize them a bit for fun.
Paint the top. We just bought little samples of the color we wanted and mixed in a bit of anti-skid paint additive to provide some traction so the top of the box wouldn’t be slippery. It works amazingly well. I hope to gosh I don’t fall on my knees on top of this thing or I’ll have quite the raspberry! We each used two coats of paint to make the color rich and I’m so happy with how it turned out!
Stencil the sides. We thought if we added the height of our box to the sides using a stencil it would give it a really finished, polished look. I love how that part turned out too.
We went to Menards for some things we needed and meant to get stencils but we forgot. So instead, I just opened up MS Word and used the “Stencil” font to create my own stencils. I printed them out and then Roger cut out the numbers so we could use them as stencils. We didn’t have any other paint around so we just colored it in with a black permanent marker.
I’m so in love.
When you don’t wanna spend a ton of $$ on equipment, build your own when you can! There are so many great tutorials online to get ideas and know-how from.