How to Make a Kettlebell Mold

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Kettlebell weights are heavy, rounded exercise tools that you hold by an exposed handle and use for swinging exercises. A cheap alternative to purchasing kettlebells from a commercial retailer is to make your own kettlebells. By calculating the diameter of bell needed to create your desired weight, you can then form a mold using a simple inflatable ball, and pour your kettlebell for only the cost of the products that you use to make bells of multiple sizes.

Things You'll Need

  • Calculator
  • Inflatable ball
  • Pump
  • String
  • Tape measure
  • Plaster of Paris
  • Rebar
  • Vice
  • Metal pipe, 6 inches long
  • Cement mix

Calculating Circumference of Ball

  • Divide the desired weight by the cubic-foot weight of your concrete of choice, displayed on the bag, to determine the cubic feet of concrete required.

  • Multiply the result by 1,728 to convert into cubic inches required.

  • Multiply the volume by 3/4.

  • Divide the result by pi.

  • Take the cube root of the result to determine the radius of the ball required.

  • Multiply the result by 2, and the result of that by pi to determine the circumference desired.

Making the Mold

  • Inflate ball to the desired circumference, wrapping a string around the ball and measuring the length of the string to determine the circumference.

  • Mix the plaster of Paris according to your brand of choice's recipe.

  • Cover the exterior of the ball with a layer of plaster, at least 1 inch thick, leaving a slot at the top of the ball open for the insertion of the handle, then leave to dry.

  • Deflate the ball once the plaster has dried until the ball is deflated enough to be removed out the hole in the top of the plaster mold.

  • Thread rebar through the pipe piece, using as many pieces as you can fit.

  • Secure one end of the rebar pieces in a vice, and pull on the opposite end while wearing work gloves to bend the rebar down and underneath the pipe piece.

  • Repeat for the second side of rebar so that the pipe makes a handle and the rebar is bent underneath the handle.

  • Mix the concrete according to the recipe for your brand of choice and pour into the ball mold.

  • Insert the rebar down into the wet concrete, creating a handle for the bell.

  • Apply wet concrete around the rebar pieces so that the concrete reaches the pipe.

  • Break the plaster mold off of the bell once the concrete has dried.

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