How to build a CrossFit Peg Board: A Simple DIY project for your garage or home gym

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Recently my friend opened his own CrossFit Affiliate Box “The Standard” in downtown Toledo, Ohio. I wanted to do something for him.

I had been to other CrossFit Affiliates in the area but had never seen one that had a climbing pegboard. These were really made popular during the CrossFit Games and gave the athletes a seemingly insurmountable obstacle.

Since then, garage’s and gyms all over the world have been producing them.

I decided that I wanted to make a climbing pegboard myself, and gift it to my friend for his grand opening.

I enjoyed it so much that I wanted to share how I did it with everyone who reads this. Not only that but there will be a drawing that you can download with dimensions and everything to make your own exactly how I made this one.

Let’s get started.

Materials you will need

  • 2” x 12” x 8’ Pine Lumber ($20) - Bought at Lowes

  • 36” Length Dowel Rod 1 1/4” Diameter ($4) - (I used Oak) - Bought at Lowes

  • 1 1/4” Bore ( I had one of these already)

  • High Powered Drill or Drill Press (Already had)

  • 2” x 4” x 2’ (this is to lay under the board will you are drilling holes to prevent splitting)

  • Pencil (Already Had)

  • Ruler or Measuring Tape (Already Had)


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Step 1) Measure and Plot the holes

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The first thing you will need to do is measure out where you want the holes for whatever pattern you might be using.

Measure twice, plot once. Line up several different dimensions to ensure that you are putting the hole points at the proper locations.

This should be the step that you take the most time on, and if you plan on making several of these in the future, take the extra time to make a template that will make doing these even more efficient in the future.

I actually made a cup of coffee, brought the lumber into the den of my house and measured and plotted it there. I was jamming to some music that I had and pretty much made it an enjoyable moment.


 

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Step 2) Drill Pilot Holes

Once you have everything plotted out it’s time to drill some pilot holes.

One thing to note is to use a very small drill but for this. Mainly because your boring tool needs to have a center to stay aligned with. Without a center your boring tool will bounce all over the board and make the holes look choppy.

I used a regular drill with enough power to drill for over an hour, without dying.

As far as the boring bit goes, I used a Milwaukee Flat Wood Boring bit. It worked great and took almost no time to core out the lumber. You can also use the 1 1/4” Hole Dozer, that also worked great, and it comes with a pilot hole drill bit already.


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Step 3) Bore the Holes and make the pegs

You already had the pilot holes drilled whether you used 2 different drill bits or you used the Hole Dozer. Now you just have to finish the holes at 1 1/4” Diameter.

The only holes that don’t get 1 1/4” diameter are the mounting holes. Those need to be cored about 1/3 of the way through the lumber and have a diameter of 1”, then you need to drill a hole all the way through so that it’s slightly under 1/2'“ or whatever the size of the mounting bolt you will be using.

The Standard used 1/2” x 3” Tapcon Concrete Mounting bolts.

To get the pegs, I made them 6 1/2” long. That’s it. Just cut them to length and they are done.

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Step 4) Sanding and deburring

Once you are done boring the holes, then you can move on to the finishing touches.

I used an electric sander and then I outsourced the rest to my two daughters and had them go around the edges of the holes, to make sure the burs were out. Then I made sure that the pegs could fit through every hole.

I used 400 grit and 200 grit sand paper.

It made the edges nice and smooth and then I rubbed my hand across the whole thing quickly to make sure that there would be no splinters.

Take your time with the sanding and make sure it is smooth.

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Step 5) Finish and Hang

Once you get it to where it is smooth enough for your liking, then go ahead and find a place to hang it. Use the 6 mounting holes to hang it.

They are staggered a little over 40” apart vertically and about 8” apart horizontally.

Once you have it hung, now you have a new challenge.

Good luck.

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If you have built a pegboard, I want to see it. Share a picture with me on Instagram @360manproject, and use #360manproject.

Stephen


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