Build this mobile gym equipment organizer with custom storage space for dumbbells, kettlebells, and yoga mats.
Time A full day
ComplexityIntermediate
Cost$100 to $300
Introduction
Learn how to construct a mobile three-tier home gym storage caddie that makes pre-workout setup and post-workout cleanup quick and easy.
In my home, I had dumbbells tucked under a chair, a yoga mat leaning in the corner and kettlebells put away in a closet. Having my workout equipment here and there drove me nuts. After failing to find something suitable on the internet, I decided to take things into my own hands and make a custom home gym storage caddie. Here I share the steps and all the measurements so you too can make it at home.
Project Overview
Cutting List
| KEY | QTY. | PART | DIMENSION |
| A | 4 | Long side of shelf (bottom and middle) | 1-1/2″ x 1-1/2″ x 28-1/2″* |
| B | 6 | Short side of shelf | 1-1/2″ x 1-1/2″ x 12″* |
| C | 2 | Long side of shelf (top) | 1-1/2″ x 1-1/2″ x 25-1/2″* |
| D | 4 | Leg | 1-1/2″ x 1-1/2″ x 26-1/2″ |
| E | 6 | Cross support | 1-1/2″ x 1-1/2″ x 6″ |
| F | 2 | Kettlebell support | 3/4″ x 5-1/2″ x 18″ |
| G | 2 | Angle iron | 1-1/2″ x 1-1/2″ x 22″ |
*- to long side of 45-degree mitered ends
Tools Required
- 1-3/4" Forstner bit
- 1/8” Drill bit for metal
- 18ga. nail gun
- 18ga. staple gun
- 2” Forstner bit
- 3” Forstner bit
- Angle grinder w/ cutoff and flap discs
- Biscuit / Plate joiner
- Countersink drill bit
- Deburr/counter sink bit for metal
- Detail sander
- Drill
- Drill press
- Mallet
- Miter saw
- Paint brush
- Trim router w/ 1/4" round-over bit
Materials Required
- #10 Wood Biscuits
- 1 - 1x6x4' maple
- 1 - 2x8x8' maple
- 1-1/2" brad nails
- 1-5/8" screws
- 1/2"x 3/8" crown staples
- 1/8" x 1-1/2" x 1-1/2" x 4' angle iron
- 150-grit sandpaper
- 2" Screws
- 2” Nylon Webbing
- 220-grit sandpaper
- 4 - 2" casters w/brakes
- Handle
- Polyurethane
- Shop rags
- Spray paint
- Wood glue
Project step-by-step (11)
Cut the wood and angle iron
Pre–seal the wood with a coat of polyurethane finish and let it dry before cutting.
Use a miter saw to cut the long (A and C) and short (B) sides of the shelves, the legs (D), cross supports (E), and the two pieces of the kettlebell support shelf (F). Use an angle grinder with a cutoff disk to cut the angle iron (G) to the length for the dumbbell support on top of the unit.
Build the outer frame for the shelves
Glue and nail the mitered ends on the long (A) and the short sides (B) to create frames for the bottom and middle shelves. Do the same with the long (C) and short sides (B) of the top shelf.
Use wood glue and 18-gauge brad nails to pin and hold the miters tight. Then, to strengthen the joint, toescrew a 1-5/8 in. screw from the underside into each corner where it won’t be visible. Be sure to pre-drill the hole to prevent splitting the wood.
Install the legs
Join the top, middle, and lower shelf frames to the legs (D) using wood glue and two-inch screws. Start by installing two legs into the inner corners and flush to the bottom of the bottom shelf frame on one end of the bottom and middle shelf frames. Install the second set of legs (D) square to the first and 18 inches over on the same frames.
For the top shelf, install the legs tucked into the opposite corners. This will create a storage area for a yoga mat on the middle and lower shelves on the other side gym caddie. Space the top and middle shelves 10 inches apart and the middle and bottom shelves 12 inches apart.
Install the cross supports
Place the cross supports (E) at each end of each shelf that sits between the legs (D). On each side of the cross support (E), secure it with a toescrewed 1-5/8 in. screw on its underside, ensuring that the hole is predrilled to prevent splitting the wood. This will hide the screws used to secure the legs to the shelves and give each shelf shear strength.
Build the kettlebell support
Use wood glue and a biscuit joiner to join the two kettlebell support pieces (F) together. Clean up any glue squeeze-out with a damp shop rag and allow the glue to fully cure.
When the glue has cured, determine the ideal placement for your kettlebells depending on their size. Using a drill press, drill holes with a Forstner bit or hole saw for each kettlebell to sit in. I found that a 1-3/4 in. hole worked well for a 5 lb. kettlebell, 2 inches for a 10 lb. and 3 inches for a 15 lb.
Soften the top edges of each drilled hole with a 1/4 in. round over bit on a router. This will also chamfer the upper edge of the circle and allow the kettle bells to sit snugly in place.
Install the kettlebell support
Using an 18-gauge nail gun with 1-1/2-in. brad nails, secure the kettlebell shelf (F) so it spans between the long sides (A) of the middle shelf frame between the legs (D).
Install the nylon webbing
Using a staple gun with 18-gauge, 3/8-in. x 1/2-in. crown staples, install the 2 inch wide nylon webbing, stapling on the underside of the lower shelf frame. Install the three longer lengths first, starting in the middle of the shelf, leaving a minimal gap between them. After the longer lengths have been secured, weave each shorter row in and out between the longer lengths to create a hatch pattern in the nylon webbing, leaving a 3/8-in. gap between rows and securing with staples as you go.
Install the casters
Secure the casters to the cart’s underside, ensuring that the screws are positioned where they seat well into the end grain of each leg (D).
Install the angle iron
Soften the sharp corners with a sanding flap disc on an angle grinder. Spray paint the angle iron and allow it to dry.
Place the painted angle iron on top of the gym caddie and mark where you will pre-drill holes for installation, either into the short ends of the upper shelf frame (B) or cross supports (E). Pre-drill your holes on the drill press with a 1/8-in. metal drill bit and countersink with a metal de-burring bit to allow the screws to lay flush when installed.
Ensure the spacing of your angle iron (G) works well with your dumb bells and secure with one-inch screws.
Install the handle
Center your chosen handle side to side and top to bottom on the top frame end (B) opposite the yoga mat storage and secure it with screws.
FAQ
Will gym equipment rust in a garage?
Yes, as garages tend to lack insulation and climate control, they are susceptible to rusting gym equipment made of ferrous metals like steel or iron.
What flooring is best for a garage gym?
Rubber and PVC floors are two of the best flooring types for a home gym, especially those in garages or basements with a concrete floor. Rubber is also a good choice because it adds valuable padding, which takes pressure off your joints during strenuous exercise.
