Here are some pictures of my rack. I've made it from 90mmx90mm poles (which are strangely enough 85x85), and 100mmx50m(=95x45).
It took around 25 hours to build I think. It was the first thing I ever built in wood. If I'd known the construction time beforehand, I would have bought a metal one. But I thought I could do it over the weekend, and when I couldn't I was commited since I had already bought all the materials and tools. I took the plans from (
http://www.home-gym-bodybuilding.com/ho ... -rack.html) and made some small mods: I extended the base outriggers also to the front of the rack, so it won't tip over if you do some acrobatic pullups. I fixed the pullup bar in the poles instead of the connectors, which is stronger and you have more space. The bars are 1inch ID, around 34mm OD, which is rated to 340kg/1m I believe.
Without tools, I think it cost around 200 euro (screws+wood, no workhours included

) I hanged on it with some heavy guys, together 270kg, and not a single sound or movement, so it'll safely hold 140kg, the max I can imagine myself using.
The only thing is I need to stiffen it up in the side dimension. In the front-back dimension it is totally rigid, but in the left-right dimension there is a little bit of play that I want to eliminate.


