Project by Kaizen DIY
Introduction
What’s up, everyone? I am back with a new tutorial after taking last month off for a vacation in Costa Rica.
It was a much-needed break in a fantastic place. If you want to hear about that, check out the latest Do You Even Lift Bro podcast episode, where we discuss trying to get in a good workout on vacation.
Today’s tutorial is for a simple calf raise block; it’s a quick build and super nice to have in the gym.
Here’s a basic outline of this article:
Video
Video instructions can be found in the video below.
Instructions
I’m using 4x4s and lap joints, but if you want to, you can use 2x4s, lay them down, secure them, and call it a day.
I am using scrap pieces of 4×4 for this. I’ll be using lap joints to give myself a slightly higher elevation than just having a 4×4 sitting on the ground.
For those unfamiliar with the various types of wood joinery, a lap joint is where you cut a little notch out of each piece of wood, so they sit together like Lincoln logs. You can use a sliding miter saw with a depth stopper or a radial arm saw, but those can be sketchy or just about any circular saw. I’m using my sliding miter saw.
Once you’ve marked your width and set your depth, make passes until the entire section is cleaned out.
I do this in the center of the two shorter pieces and the ends of the longer piece.
Once those are all cut, I use a stopper to set up my 45-degree cuts on the shorter pieces. These cuts serve no function but are an easy way to elevate the design.
I run those pieces over my table router and round over bit. You’ll recognize this step if you’ve seen any of my previous tutorials. I love my round-over bit; it makes everything look nicer.
Then, I use a combination square to mark the holes to make sure they are even and symmetrical.
A particular drill bit set for this one. These holes are drilled with a countersink bit.
Before I fasten these pieces together, everything needs to be sanded. It is much easier to sand these pieces evenly before assembly.
I apply a healthy amount of wood glue and spread it out across the surface of the joint.
All of the pieces fit together perfectly. This is so satisfying.
I fasten each side with two 2.5″ wood screws.
Remember that particular drill bit set I mentioned earlier? This is the other part of the set. This bit is a wood plug cutter. I cut four pine plugs to match my pine 4×4.
Add glue to the hole before popping the plugin, tap it with a rubber mallet, and cut off the excess with a hand saw.
Side note, always cut away from your hand.
I go over the plugs with the sander to smooth everything out.
An ebony wood stain is used on this one. The dark rich tone serves this project well.
I apply a healthy amount of stain and wipe off the excess before letting it dry overnight.
The entire top piece should be grippy, so I use skateboard grip tape. I cut down the length, and the width is just right as-is.
It covers the top and sides perfectly.
And there you have it – a calf raise block. I love how this thing turned out.
Before assembling, I forgot to take photos of the measurements. You can use whatever dimensions work for you, but here is what I did.
Okay, I take it for a spin, and it is perfect. Everything I wanted and more.
That’s it for this build. Thanks for checking it out. Let me know what other projects you’d be interested in seeing.
Recommended Materials & Tools
| Materials: | Link #1 | Link #2 |
| 8ft 4×4 | Home Depot | |
| 2.5-inch wood screws | Amazon | Home Depot |
| Skateboard grip tape | Amazon | |
| Titebond III wood glue | Amazon | Home Depot |
| Minwax Ebony Wood Stain | Amazon | |
| Tools: | ||
| Dewalt sliding miter saw | Amazon | Home Depot |
| Dewalt impact driver | Amazon | |
| Dewalt 20v random orbit sander sander | Amazon | |
| Drill press – alternatively, the holes can also be drilled using a cordless drill. | Amazon | Home Depot |
| Wood Countersink Drill Bit Set & Wood Plug Cutters | Amazon | |
| Router and table | Amazon | |
| 1/4 inch round over bit | Amazon | Home Depot |
| SUIZAN Japanese Flush Cut Saw | Amazon |
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