Building a squat rack...need suggestions

[Robertdeuce]

I'm building a rogue style squat rack but I'm in need of suggestions on how to cut 1" hole in 11 gauge steel.
There are 10 post and about 200 holes per post. I've been doing a little searching and I've narrowed it down to a low(100-250) rpm drill press. My question is, which drill press has rpms that low? Also, what would be the best bit/hole saw to use with the press?

 

[bcradio]

By the time you buy all the tools and equipment and steel and stuff to paint or powder coat it, you might be better off just buying one. I love welding stuff and I've welded a number of things for myself around the house and for family members, but I bought my power rack already made. It was much cheaper it came out perfect and has everything I wanted on it. It did cost quite a bit, but it was worth it to buy it once and buy it right.

 

[ttpete]

I'd go with a Hougen Rotabroach. Run it real slow.

If you can get hold of a mag drill and maybe set up on a steel table, it would run slow enough. The other thing might be a bench top mill.

 

[619DioFan]

Not sure which rogue rack you are trying to copy but it sounds like one of their monster racks ( rm-6 ) I think you will lose your mind drilling all those holes ( I know I would ) I have built gym equipment before and can tell you that when it comes to welding it together and you do not have a jig , parts tend to move and then things do not line up right. IMO I would buy a good squat rack( used ) them modify it if you like.

 

[Robertdeuce]

Not building it isn't an option(material is already bought)
If anybody has any other suggestions apposed to mine, I'm all ears. Thanks for the drill press suggestion BTW.

 

[619DioFan]

A new mag drill will run between 500-800 dollars. not sure what the cutters run.a benchtop style 12 speed drill press from HF runs about 140.00. the slowest speed on that is around 300 rpm. might do. a 1 inch drill bit with a 1/2 inch shank runs about 20.00 on amazon ( irwin brand )

 

[PhysicsDude]

I would use a carbide hole saw.

Make sure when you buy one its actually a 1" hole saw (or 25mm) and not a "1 inch conduit size" hole saw which is actually 1 3/8".

I've cut many holes through 1/4" steel plate with them with no issues. I don't know how long it would last, but if used properly in a drill press I think it would do quite a few holes. Just take the pilot bit out or pre-drill it with a 1/4" bit.

They should be fine to 400-500 RPM if you're easy on them.

https://www.amazon.com/dp/B01I416TR4/?tag=atomicindus08-20

 

[Lelandwelds]

https://www.roguefab.com/product/drill-press-reduction-kit-161-ratio-12-belts/

woodworking drills turn too fast and need the above. If you're buying a drill press, find a old pre 1980 ish floor drill press. If it has 3 phase, the motor should be small enough to be driven by an affordable VFD. You can turnit at any speed within reason without steps. Or, the steps will overlap.


Mag drill needs a flat stable surface for the base or you break cutters.

A fab shop with about a 100 ton ironworker could do it quick and easy and (probably ) cheap. Probably has the steel in stock for no drop.

 

[Sco Deac]

Check to see if where you live has a shop co op with the right type of equipment. If you don’t have the need for this type drill after the project, a membership could be the way to go. I am thinking of something like this. http://www.techshop.ws/locations.html

 

[KBATN]

I have a squat rack. I think i paid 250$ for it. I don't know how much your material and equipment will cost but maybe better to just buy a rack?

 

[MarkMog]

I owned a private fitness facility for almost 15 years. Looked for used on CL, you won't be able to build a safe product for the investment of time and materials that you can get with a used commercial unit.

 

[Lelandwelds]

Not building it isn't an option(material is already bought)
If anybody has any other suggestions apposed to mine, I'm all ears. Thanks for the drill press suggestion BTW.

If you are committed, locate a local iron working shop with a big ironworker . This one will punch 1.125 diameter hole in 1 inch plate @ 25 holes/min. Rates vary a LOT. I last paid about 30 cents / hole

https://www.megafab.com/piranha/singleoperatoriw/singleoperatoriw_p-90.html

 

[matt_i]

I have yet to see an ironworker that will punch square tubing of 11ga or 1/8" wall......

Blair holcutter is what I would use. Easy money with a cordless 18v to 20v drill. Will take awhile tho. But the holes will be clean. I'd layout w a pencil then optical center punch the spots.

 

[rsanter]

I sold one for $50 to get it gone

Bob

 

[Lelandwelds]

I have yet to see an ironworker that will punch square tubing of 11ga or 1/8" wall......

Completly do able but a bit harder to find. Each size and wall of tubing takes a different die. Call around. Find some one working with the size you need.

The factory doesnt wish that hole in there.

 

[Ricoch3T]

plasma table at a shop might work

 

[kctyphoon]

This seems like too much of a hassle.. just my opinion.. it would be a different story if you had a metal fab shop, but it seems like that's not the case..