Best DIY Calf Raise Block Design
How to Make a Calf Raise Block for Your Home Gym
By: Jeremy Fox, CNC, CPT – Published: August 29, 2024
In this step-by-step guide, I’ll show you how to make a sturdy calf raise block using just a few tools and basic woodworking skills. So you can take your home gym to the next level.
If you’d rather watch and listen, this 5-minute video shows you how to build this calf raise block. Click HERE to subscribe to my YouTube channel for more home gym videos!
Calf raises in your home gym typically involve standing on a weight plate or another sturdy object.
However, this can result in a limited range of motion at the bottom of the raise. These makeshift options are often slippery or unstable, which can be dangerous.
The solution is a purpose-built calf raise block like the ones you can buy online. But if you’re frugal like me, it’s hard to justify paying $70 for a chunk of metal that you only use for one exercise.
I decided to build a calf raise block for my home gym. While I consider myself halfway handy, I’m definitely not a DIY expert. So if I can build it, you can too!
DIY Calf Block Design
I started by researching DIY calf-raise blocks on Reddit and YouTube and saw that most designs are flimsy “H” frames made from 2x4s. Meanwhile, the more robust calf blocks are made from 4x4s.
One of the coolest designs I found features notched supports to create an angled footboard. But the 2×4 construction still looks a little too flimsy to me.
Kaizen DIY Gym built this sturdy calf block.
Reddit user u/DeweyDewd posted this DIY calf raise block in the r/homegym community.
My idea was to combine the best features of these designs. I wanted a sturdy calf block made from 4×4 lumber with an angled footboard.
I sketched a design with angled notches cut out of the two support pieces so the footboard sits at a 22.5-degree angle. Being half of 45 degrees, I thought this angle would be both aesthetic and functional.
I used this basic drawing to plan out my DIY calf block build.
And the end result is exactly what I wanted!
Then, I went to the hardware store to get supplies. Here is a list of the items you’ll need to build this calf raise block:
DIY Calf Raise Block Supply List:
- A 4-foot piece of 4×4 lumber (I used white pine)
- A carpenter’s square and pencil for marking angles
- A hand saw for cutting wood
- 3″ wood screws (#10)
- Sandpaper (80, 120, 220 grit)
- And non-slip grip tape
It’s also essential to wear eye protection at a minimum when working on projects like this. I also recommend hearing protection if you’ll be using loud power tools. Safety first!
Use the arrows to see pictures of all the tools and supplies needed.
How to Build the Calf Raise Block
Next, I’ll walk you through how to make this calf raise block step-by-step.
1. Cutting boards to size and shape
The first step is cutting the 4×4 in half to create 2-foot-long pieces. You can do this with a hand saw, but I used my table saw to save time.
I set the blade at about 3″ cut depth and made a partial cut. Then, I flipped the board and cut the rest of the way through.
Next, I cut one of the 2-foot pieces in half again to create 1-foot pieces for the supports.
Two passes with a table saw cut through the 4×4. If you have a miter saw, it would work best.
You should end up with one two-foot piece and two one-foot pieces.
The next step is cutting out the angled notches on the support pieces. This step is the trickiest because it requires careful measuring and cutting.
First, I used the carpenter’s square to measure a 22.5 angle on one end and cut it off using the table saw.
The carpenter’s square makes marking angles and making square lines easy.
Mark both sides like this, then connect the ends of the lines on the top face.
Then, I measured the 22.5 and 67.5-degree angles for the notch. I also traced around the profile of the 4×4 to get the actual shape of the cutout.
I tried using my table saw but couldn’t adjust the blade to cut the larger angle. So, I ended up using the hand saw for this step.
The cuts were far from perfect. But don’t worry—you can sand it down later to get a perfect fit.
Sawing the angles by hand takes a little skill and a lot of patience.
The rough cuts look ugly, but we’ll clean them up later.
2. Pre-drilling the screw holes
Next, I lined up and marked the placement for three wood screws to fasten the footboard to the supports. Then, I pre-drilled holes to prevent the wood from splitting.
I accidentally drilled a hole in the wrong spot, but it’s not a big deal because the screw holes are out of sight on the bottom of the calf block.
Next, I used a countersink bit to ensure the screw heads sit flush with the face of the board. You don’t have to do this step, but it makes it much easier to get the screws in so they don’t stick out the bottom of your calf block.
Pre-drilling holes for wood screws.
Countersinking holes.
3. Fitting and sanding
At this point, I wasn’t happy with how the boards fit together. You can see large gaps partially because of my cuts but also because the 4x4s aren’t perfectly square.
So, I used 80-grit sandpaper and a sanding block to shave down the high spots. Now, the boards fit much better with fewer gaps.
One of the large gaps shown on the corner.
The gap is almost gone after sanding down the joints.
This next step isn’t necessary, but sanding all the surfaces prevents splinters and gives the calf block a sleeker finish. So, I hit all the surfaces with 120 and 220-grit sandpaper until they were nice and smooth.
You could also stain or seal the calf block at this point. But I chose to leave the natural wood finish.
I used a random orbital sander to speed up the process, but you could do it by hand.
All surfaces sanded and ready for assembly.
4. Assembly and grip tape
Finally, we’re ready to put the pieces together. I used 3″ long general-purpose indoor screws since I have a basement gym. You may want to use deck screws if you have a garage gym or an outdoor setup.
The screws sit nice and flush with the bottom of the calf block, thanks to those countersunk holes.
The last step is applying anti-slip tape to the footboard. My home improvement store only had 2″ wide tape, which would work with two strips. But this would most likely wear out or peel up at the seam over time.
So, I ordered this LifeGrip 4″ tape on Amazon, which covers the entire face of the footboard with one piece. I cut it down to size, lined it up, and pressed it firmly onto the wood.
And this is now the finished product.
This 4″ grip tape fits perfectly on the face of the 4×4 (3.5″ wide) with a little extra to wrap around the edge.
Finished calf raise block ready for use!
Testing the Calf Raise Block
Once assembled, this calf raise block is rock solid. I love how beefy it is, yet it looks minimal and clean.
When testing it out in my home gym, the calf block didn’t budge even under hundreds of pounds of load.
I also like how deep of a stretch you can get at the bottom with that angled footboard. Plus, the grip tape makes it feel like your feet are glued to the platform so you won’t slip off.
This thing is beefy and built to last.
The angle allows a deeper stretch in your calves at the bottom.
Calf Raise Block Project Summary
The materials for this calf block project only cost about $15. I also invested in a new handsaw and carpenter’s square, which I can use for future projects.
The entire build took several hours, including trips to the store, charging drill batteries, and filming the process. But with what you’ve learned here, you could probably finish it in a few hours.
With this DIY project, you can create a calf raise block that will save you money and provide you with commercial-quality gym equipment that will last decades.
DIY Calf Raise Block Time and Cost
- Estimated Build Time: 2-4 hours
- Materials: $15 (wood, screws, tape)
- Tools: $20 (carpenter’s square, hand saw)
- Total Cost: $35