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Indoor Dry Tooling - Your Home Boulder Wall Print
Tuesday, November 3, 2009
Lots of crowded indoor gyms but still nowhere to push your pump limit?

Image

November is splendid for outdoor climbing. The ice and mixed season is coming along. Never mind the rain.

The proper thing to do is obviously to turn off your computer, quit your daytime job and move to wherever conditions are right. If you get that right, then please stop reading here.

Even a soggy place like Stockholm offers steep enough crags. Still, without daylight and with respect to the local crackoholic ethics you might need to find alternatives to tearing beloved sport and trad routes apart with your Darts and Nomics. As long as no commercial gym accepts dry tooling, you have to make it happen by yourself (infallibly with less grandeur).


Image
Done - just add holds.


This basic configuration will cost you less than a year in the gym and will keep you off the rock for one weekend of construction work.


Material
The bulky stuff fits on the roof of a car (with rack and straps):

  • 2 construction plywood sheets 2400x1200x18 mm,
    extra for kicker panel
    (might be discarded at construction sites after pouring concrete)

  • Framing studs from 2”x4” = 2400x45x90 mm lumber
    (might be left over at home construction sites)
    3 for header, footer and kicker panel
    5 for joists,
    1 for joist blocking


Image
No trailer needed.


…and in the car:
  • 2 liters of (discarded) paint
  • 1 box of 100 framing screw Spax T25 6x80, self-plunging.
  • 1 box of 200 decking screw Spax T20 4,5x40, self-drilling, self-plunging. 
Image
T-nut and Spax boxes. T30 bit, 12 mm drill, bit screwdriver.


  • Concrete expansion anchors or whatever suits your wall and roof best
  • 7 boxes of each 50 T-nuts (inslagsmutter, Einschlagmuttern) Würth M10/H16x25. Negotiate the price.
Image
T-nuts.


  • Grips / holds with corresponding M10 6 mm plunged head and 8 mm straight head hex socket bolts. Different grips require different bolts (length and head). Full length threads are most versatile.
    Footholds / chips with screws.
    Maybe second hand, worn out by your local gym.
    For dry tooling, roughly cut wooden studs and plywood fragments will sometimes outperform commercial grips and will also provide a substitute for one-hit-wonder ice)
  • Crash pads, mats, mattresses, foam, padding. Start collecting. This is expensive even for large gyms.


Image
No pro tools needed.


Tools
  • Tape measure
  • Level
  • Pencil, marking tape
  • Saw
  • Hammer
  • Power drill with support for perpendicular drilling, extension cord
  • Drills 12 mm for T-nuts, 6 mm for framing screws
  • Bit screwdriver
  • Bits T20, T30 for wood framing and decking screws.
  • Bits for concrete expansion anchors or corresponding bolts, maybe PZ3.
  • Bit 6 and 8 mm hex socket and hex key (insexnyckel) to attach the bolts of the grips.
  • Clamps
  • Paint roller, paint tray
  • Ladder or stool
  • Saw horses, workbench


1. Find a location with minimum 2500 mm from floor to ceiling (and corresponding floor area, quite a lot). Also, you need workspace. 

2. Check out the configuration of favourite walls in nearby gyms.
Borrow someone's smart-phone to measure the angle of different overhangs correctly.

Check photos of dry tooling and ice competition walls. Maybe you want hanging features, a roof traverse etc.





Love to everyone at Karbin for your ecouraging commitment.

3. Spend time on design and a detailed drawing, solving every little issue in advance. Check your design with positions of  electrical outlets, lights, heating, water pipes etc.
How much overhang do you prefer? 10 degrees is too little, 45 is too much. A steeper wall will be more like a floor to construct. Don't underestimate the added weight and workload associated with anything steeper than maybe 30 degrees. Anyway, for each sheet of 2400 mm plywood, 5 studs (= joists, framing bars) from 45x90 mm lumber seems to be standard here and now for a 25 degree wall (given that the sheets are landscape/horziontal and not portrait/vertical) 

Now simplify your construction to reduce material, work and cost by at least 50 percent. Horizontal or vertical panels? Will there be any leftovers? Do you really need  T-nuts all the way down?

4. Make a shopping list of everything you fail to find second hand.
Compare prices of a few suburban construction markets. Negotiate prices and make your choice. Be careful not to accept any lumber that is not completely straight (this will disqualify about 50 percent of what you find in the shelf), else the plywood won't fit.

5. Find out the exact locations of supporting structures in roof and walls, if not concrete. Use a stud finder, or drill a 1 mm hole from above or behind for examination to know exactly where to attach your contstruction.
Mark the exact postitions of kicker panel and roof stud on floor, walls and ceiling using tape.

6. Assemble a kicker panel (a vertical bottom section required for steeper walls) from 2 horizontal studs and 5 binders, joined by single vertical framing screws. Put it in position. You might not need to attach it to the wall.

Image
Kickboard in position.

7. Attach a stud to the ceiling. You will need some assistance here. Use another pair of studs to squeeze it in place while working.

Image
8. Roughly cut a first joist, hold it in place and use a pencil to mark the exact cuts to make it join kicker panel with roof stud. You may have to make a second cut in both ends to make it fit, depending on the wall angle of your design.

Image
Joist attached to roof stud.

9. Cut the first joist, confirm and adjust.

10. Mark and cut the remaining joists, using the measures of the first but adjusting for irregularities in lumber, floor, walls and roof.

11. Attach the joists using a vertical framing screw, supported by another one inclined from the side of the joist. Joist hangers (balkskor) might be overkill for anything overhanging less than 30 degrees, depending on the supporting structures of ceiling and walls. Check every position for square (else the plywood won't fit).
Image
Framework ready to be decked, with joists and blocking in level.


12. Now measure the actual length needed for each horizontal joist blocking (kortling). Cut and attach, with double horizontal framing screws where possible. Assemble with the screws inclined (skråspikning) where the end of a stud is blocked by another.

It is easier to attach the horizontal blocking in one piece behind the vertical joists, but then the seam between the plywood sheets will be unsupported. 
On the other hand, more than a top and bottom blocking per 1200 mm horizontal/landscape plywood seems to be overkill.

13. Mark the positions of the T-nuts on one sheet of plywood, using tape measure and pencil. A grid of 160 mm squares might fit the sheets without  colliding with the framework. The kickboard will have no grips (maybe screw-on foot chips) and thus need no drilling.

14. Clamp the two plywood sheets together and start drilling. If these holes are anything less than perpendicular, then you won’t be able to attach grips. This cannot be fixed afterwards. Freehand drilling will hardly be accurate enough, get some kind of tool or support for a 90 degree angle.

Image
Plywood sheets clamped to rationalize drilling.


15. Paint the plywood using a roller - while still on the ground.

16. Attach the T-nuts, using a hammer. Attach a pair of jug grips on each sheet to make sure the drilling was accurate enough and to make it easier to handle the sheets.

Image
Framework decked. Blocking attached with double horizontal framing screws where possible.

17. Attach the plywood sheets, using decking screws. No drilling needed. You need assistance to keep each sheet in position. Start with one screw in each supporting stud, then dismiss your assistant and add screws roughly every 200 mm.
With this basic design you don’t need to cut the plywood sheets, except for the kickboard.
Image
Kickboard decking inclined to connect to the next plywood sheet.

 

18. Attach grips. Remember a steinpull (dry tooling undercling) puts an immense leverage on any grip. Footholds won’t be necessary as long as you accept to attack the wood with your front points. 

Image
Uppermost plywood covering roof stud. Could be replaced by top jug.


19. Provide for a safe landing. Cover it with something that will accept your crampons, such as a mat.

20. Get some company and start working out. Remember you now have to spend more time in this garage than in the gym to break even in a year…

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