Outdoor Pullup Bar

This summer I wanted to replace my indoor pull up bar for a sturdy outdoor one. This project took me 3 weeks to finish but I took my time doing this. Also a disclaimer starting off make sure you check utility lines underground by reaching out to 811 the call before you dig line. The method I used to put this pull up bar in was with concrete and burying in the ground.

Materials I used was

1. 2 pressure treated posts
2. 2 50lb bags high strength concrete (not quick set)
3. Galvanized post recommended 1.5 - 2 in diameter length will vary
4. Galvanized fasteners as listed
5. x2 5/16inx4in hex bolts
6. x4 5/16in flat washers
7. x2 5/16in hex nuts
8. 5/16in drill bit
9. Fostner bit that is at least .25 or .15 larger than bar diameter
10. Concrete mixer (for drill)
11. 5 gallon bucket or larger
12. Hand Trowel or something to wipe concrete
13. tape measurer and level (longer in preferable)
14. Drill that can use drill bits and concrete mixer (obviously)

First Find a nice open spot for the bar, ensure that the posts you put in the ground have enough room on both sides, In the picture I wrote down measurements and cleaned the area till it was open, measurements were easily done on my phone. Make sure you have at least 3 feet for the bar in between the posts and make sure the posts and the holes where the posts will be aren't touching a wall or fence. and make sure you measure how tall you want the bar to be up. a great way to do this is to go to a wall on your tip toes, raise your arms up and grip the air like you would a bar then right down how tall that is with a tape measurer.

After drawing up some simple plans be sure to mark where you want to dig your holes IN WHITE, then call 811 (call before you dig line in the US) for them to send out PGE or any other technicians to check that you wont run into any important lines under your house. it is easy to set an appointment over the phone (open 24/7) and it is free. Be sure to use WHITE as other colors mean different things to them, (we ended up having to change ours to white too!)

After this you can go to a local hardware store, I went to Ace hardware to get...

1. Two 4 by 4 pressure treated posts, 10 feet tall

Pressure treated because it will be buried in the dirt with concrete, and the height will vary based on how tall you are. 10 feet worked for me because it is 2 1/2 feet in the ground and I needed the bar to be at 6' 11'' since I am 5' 8''

1. One galvanized line post 1 1/2" diameter or 2" as the bar

My bar is 3 1/2 feet long but don't go any shorter than 3 feet or much longer that 6 as that can put strain on the bar. If you need the bar cut down to size later on then you can have it cut down at the store for free as well.

1. 2 50lb bags high strength concrete (not quick set)

Make sure its not quick set concrete as that is too weak for the posts, one bag for each hole will be plenty.

1. Galvanized fasteners as listed
2. x2 5/16inx4in hex bolts
3. x4 5/16in flat washers
4. x2 5/16in hex nuts

Lastly make sure you have the other tools listed, you should be able to rent from stores or borrow from someone else if needed. and make sure you have ratchet tie downs to hold down your posts to the roof of your car and if its longer than your car (more than 3 feet over your hood and 4 feet on the back of the car) then get a red flag on your car, required by law!

The posts have to be at least 2 1/2 feet in the ground so make sure after you've called 811 and are able to dig that you have a shovel and dig bar to dig this deep and still be careful for private lines underground, ones that 811 cant detect easily. this is the most labor intensive part and took me the longest, be sure to take breaks and measure as you go! Make sure it is 2 and 1/2 on both sides so your posts aren't shorter or taller than the other. Take the time to measure and wrap the part of your posts that will be underground with a thin plastic wrap, this will help with concrete and some corrosion it may experience, even if its not touching the dirt it will help with its life span.

Now that you holes are dug its time to pour concrete and put the posts inside. We are going to be wet pouring because if you dry pour and wet it down within the hole it will not be as strengthened. so mix a bag in the bucket ensuring to pour small amounts of water in the bucket and small amounts of mix as you go. After mixing and it looks the solid consistency in the picture here you will pour a small base layer at the bottom of your hole. This should be flattened down at the bottom of your hole with a trowel or hand (use disposable gloves). after letting sit for a minute put the posts on top the small amount of concrete and start pouring the rest of your concrete making sure you spread the mix and keep the post in the middle as your go. After your done with the first post make sure to put a level on both faces of the post to ensure it is set and level, then repeat with the other post as soon as your done with the first.

After you get both posts in then you will have to wait 24 hrs from when you poured for it to be secured. Be sure to level 2 times during this process (on both faces), after you've poured it and after the 24 hrs are up, then if it needs to be adjusted you will have to push the bar hard to get it level. to make sure the bar will be parallel to the posts you have to have the posts parallel to each other, so make sure you put your bar on both outward facing sides and make sure the bar it flat against both posts. then remember how high you want the bar up, and mark where you want your fist gripped around the bar to be, the middle of it, and to ensure it's level put a string from one side to the other and eye ball how level it looks.

Now that you have both posts secured in and it has been over 24 hours we can start to drill holes. First where you marked the holes with your string from before use your fostner bit to cut as strait as you can, make sure the bit can carve out the hole so you don't have a puck stuck in the center. You have to drill at least 1/2 way if not a bit more into the wood, so hold the fostner bit up to the wood to mark how far down you have to go with the drill. Then make sure the bar can fit with these two holes and then cut the bar down if you need to. After drilling one hole be sure to put the bar in and put a level on top of the bar to make sure that both holes are level. Lastly cut the other hole and set the bar in

Now that your have the bar set in make sure to level the posts and bar one last time to be sure. Then with your 5/16 drill bit cut a hole through the wood and through the bar approximately a 1/4 into the bar, making sure there is enough wood on the end that it doesn't break, these posts are hard to get through but don't take the bar out to ensure a clean hole all the way through. use cutting oil on the drill if needed as well, then once you have a through hole on both sides put the hex bolt through with a washer on both sides and secure it down with a hex nut.

This project was really fun, and great for first post and concrete experience, I know there are plenty of ways or better ways to secure and build a pull up bar but this is the way I did it, but always be sure to have permission before building by guardian and ESPECIALLY the 811 line. I hope to have more projects to work on in the future, Thanks for checking out mine and I hope it helped you!