The Missing Barbell Link?

By R. Don Hollinger

In Equipment

February 04, 2010

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Many CrossFit athletes start with a PVC pipe before jumping to a training, women’s or full-size Olympic bar. Inventor and CrossFitter R. Don Hollinger introduces one more step to help smooth the transition from PVC to metal.

After a good warm-up, I overhead squatted 400—a PR. I’ll never forget that day.

An OHS of 400 isn’t bad for a 62-year-old who has been CrossFitting for about a year. One little detail is missing, however. While the reader might think the “400” was pounds, it was actually ounces, which converts to 25 lb. Well, it was a lot for me.

The piece of equipment that made this humble PR possible was a 5-lb. Olympic barbell I made out of common hardware or home-improvement-store parts. Even a naked Olympic barbell at 45 lb. was way too much for me, so I solved this predicament by creating a “stepping stone” barbell that has the same basic characteristics as the full Olympic bar without the high weight. I call it the “Hyperlite Bar.”

The Hyperlite Bar loaded with two 10-lb. bumpers and 40 lb. of metal plates (65 lb. total) can be dropped from the overhead position without damage to the bar. After a great effort, a big, crashing barbell bounce is a just reward. Sixty-five pounds is the max needed on the Hyperlite because one can then move to the 45-lb. Olympic bar with two 10-lb. bumper plates.

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19 Comments on “The Missing Barbell Link?”

1

wrote …

Great idea. Really like that for working with beginners and kids. Thanks!!!!

2

wrote …

Genius! Although I have been using PVC with dangling change plates trapped between the hands and shoulders for beginner squats, this fills the gap needed for progressing the fast lifts. Thank you!

3

Matt Charney wrote …

That is awesome! It would go well with my 3/4" plywood technique plates. They are 3-3/4# each so it would be a total of 12-1/2# sitting at the proper height.

I bought a couple 15# york training bars at over $100 each. If I had seen this I would not have bought those bars.

Matt

4

wrote …

This is really fantastic! I just made it, and it works great. Quick correction to table 2: you only need 1.5" of the 2" diameter PVC, not 10" minimum as the table says. Good work on this article, saved me about $100!

Kevin

5

Olivia de Santis wrote …

What a good idea!

6

Joe Marsh wrote …

Holy crap, this is genius. What a great article!
Thanks Hollinger!

7

wrote …

I just made one... it is going to be great for the people afraid to shoot a 33lb ladies bar over head. Can't wait to have someone use it!!

awesome job on these designs!

8

Brandon Nugent wrote …

Great stuff! Yet another excuse... I mean valid reason... to get some power tools :) Home depot trip is in my future.

9

wrote …

Magnificent! Thank you!

10

wrote …

Building one today! Thanks!

11

wrote …

Built one. Used it. 8 year old son loves it.

12

wrote …

This is a fantastic idea! I have had something like this kicking around in my head for a while but there were just a couple things about the sleeves I couldn't work out in my head. This address all the ideas. I will be making one in short order for my kids...in fact I will probably let them help me make it!

Thank you for sharing this!

13

wrote …

You just helped me pay for 3 more years of the CF journal. I built one of these while watching the Superbowl. Cost me $20 total and I have left over material. Saved me $80+ and now my wife has a great trainer bar to get her comfortable before going to the 45lb bars I have.

Easily one of the best journal articles recently. Every box should have a couple of these for techinique work.

Great work!

14

wrote …

This is a brilliant idea. I'm just in the process of cutting my PVC sleeves on this and I noticed one thing. For the PVC I bought from Lowes, I only have to cut the 1 1/2 inch sleeve. I also upped the ante by going for the 6 foot bar instead of the 5 footer. I'm making this for my girlfriend so she can get more comfortable with the movements before making the plunge to a 45# bar.

Thanks again for sharing.

15

wrote …

Thanks for all the comments and suggestions. I appreciate everyone taking the time to write.

It is very rewarding that athletes are enjoying the fabricating process, and sometimes sharing it with their children. I hope this barbell will help everyone experience the benefits of CrossFit.


Don

16

wrote …

Kudos! This is a GREAT bar... I made one for my daughter to start training with. It only took 30 minutes start-to-finish and looks great too. Thanks again!

17

wrote …

I've built six of these ... so far! Great tool.

One additional idea - spring clips, bull dog collars and muscle clamps all slip so much that almost any dropping of the bar necessitates readjusting the plates/collars (nothing sticks to PVC). if you cut all the PVC to six inches, you can drill a hole through the end of the bar, and build 'collars' from PVC with a pair of hitch pins to hold everything in place.

18

wrote …

Just finished building mine. My variations are:
I opted for a 6 foot piece of iron pipe.
I used my table saw to cut the pipe to 10" lengths, then split in the 1" and 1.5" PVC. I only exposed enough blade to cut the thickness of the PVC, then rotated the pipe for the cuts to length. I used 2 feather boards and a push stick to make the lengthwise slits.
Instead of sheet metal screws, I used this project as an excuse to buy a tap and die set (no really honey, I NEED the set). I used a 2 inch wide piece of 2 inch pipe to have enough room so the screws are offset at approx 120 degrees and at a different distance from the end of the pipe.
I used bat tape the length of the bar. Left over from another project.

19

wrote …

Thank you Don! My wife is looking forward to using it!

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