Making a Kettlebell Set

Introduction

In this tutorial, we'll walk through the process of making a kettlebell set tailored for your home gym. This guide focuses on using a CNC plasma table for precision cutting, followed by welding and finishing techniques. By the end, you’ll have a unique set of kettlebells, and you'll learn valuable metalworking skills along the way.

Step 1: Design the Kettlebells

• Start by modeling your kettlebell design using CAD software (e.g., Aspire).
• Create a centerline for the handle shape and use a 1.5-inch half-circle cross-section for consistency.
• Design the kettlebell's ball by splitting a circle into two halves for left and right rails.
• Factor in a flat spot on the bottom of each kettlebell to ensure they sit upright.

Step 2: Prepare the CNC Plasma Table

• Load a quarter-inch steel plate onto the CNC plasma table.
• Use the slice tool in your CAD software to divide the 3D model into quarter-inch thick layers.
• Arrange the layers using the automatic nesting feature to maximize material usage.

Step 3: Cutting the Kettlebell Pieces

• Cut the designed pieces using the CNC plasma table.
• Clean up the cut edges using a wire brush and grinder to remove slag and sharp edges.
• Number each layer to keep track of the pieces during assembly.

Step 4: Assemble the Kettlebells

• Clamp the pieces together using a right-angle jig to maintain alignment.
• Begin welding the layers together:
  • Use a wire feed welder for outer layers with large steps.
  • Opt for a TIG welder for inner layers to achieve a flatter weld and reduce cleanup.

Step 5: Grinding and Smoothing

• Start with a grinding wheel to shape the kettlebell and smooth welds.
• Switch to a flap disc for finer smoothing, which gives the kettlebell a polished look.
• Use a wire brush for final polishing to blend the metal surfaces.

Step 6: Final Touches

• For the handle, use a die grinder to reach inner areas that the regular grinder can't access.
• Apply several coats of clear enamel for a protective finish. Consider sandblasting and powder coating for more durability if needed.

Conclusion

Congratulations on completing your kettlebell set! This project not only enhances your home gym but also develops your metalworking skills. Each kettlebell should weigh closely to your target, providing a functional and aesthetic addition to your workout routine. As a next step, consider exploring more DIY gym equipment or improving your metalworking techniques. Enjoy your new kettlebells!