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Ken Leistner
Dumbbells
In a world of specialization during an era of specialization, one of the lost aspects of effective
training for powerlifters has come from the demise of dumbbell work. There are those like
Louie Simmons who combine many new, innovative approaches to training with “old school”
techniques and equipment and Louie specifically incorporates some dumbbell work into his
programs. Most do not and for those lifters who are so specialized that they take an “Eastern
European Olympic Weightlifting Approach” to powerlifting, doing only the three lifts or
some variation of them, they may never use a dumbbell in any training program. For the
powerlifters of the 1960’s when the sport was first organized, dumbbells were a staple of
many training routines as both adjunctive and “major” exercises. As our previous installments
in this series discussed the quality, differences, construction, and most other aspects of the
barbells used in training and competition, a few descriptive words are warranted for the oft-
forgotten and recently maligned dumbbells. Allow me please to first raise the hackles of
numerous readers and many more self-appointed experts who have, in the past fifteen years,
touted the praises of kettlebells.
It is true that any training modality can be effective in enhancing the muscular size and
strength of a trainee. I have often stated that the tool used in training is far less important than
the manner in which that tool is used. I believe a single, albeit lengthy, sentence can place
kettlebells and kettlebell training in its proper perspective:
Many decades ago there was a great battle that spread across the globe, encompassing the
time and effort of thousands of individuals and leading to the overhaul of long held dogma
and activity, and in that great battle, kettlebells lost, dumbbells won.
As a high school and college student seeking to become bigger and stronger (without realizing
I would also become significantly faster), I would walk or run up the steep, long stairway to
the loft of my father’s iron shop holding a York 100 pound dumbbell in each hand; I would
squat and then push my car up and down the street that we lived on (and to paraphrase from a
decades old article, “…to the delight and consternation of my neighbors” as I often vomited
either immediately after or while performing this specific exercise); I would farmers walk
(and I will reiterate and again negate the claim of another that I came to name that exercise, as
the name existed long before I did) various sections of beam to which I had welded handles.
All of the above movements and exercises like them can be done progressively, intensely, and
in a way that stimulates changes in one’s physiology, they are all useful. However,
“functional training” has now come to be spoken of as if it is both a specialized and very
special, exotic means to add to one’s levels of strength and fitness. Kettlebells are right in the
middle of this mix and more than any other “functional modality,” kettlebells have become a
“be-all and end-all” for many in the fitness field.
Kettlebells can certainly add variety to a session, as can any other unusual or infrequently
used object. There are some effective exercises like swings, presses, cleans, and even curls
that can be done but one could make the case that the same movements are as effective and in
many if not most cases, more effective and safer if performed with dumbbells. There is no
doubt that dumbbells are easier to handle and thus safer to handle. Kettlebell proponents will
make their case that it is the relative inefficiency of handling the implement that makes
kettlebell training effective. For any so-called advantage in performing a kettlebell movement
in place of the same dumbbell movement in order to “give work to the small supportive
muscles,” or “to add to the balance factor” one also suffers a decrease in training efficiency
and intensity as well as focus upon the targeted musculature. Let me add here that in my
opinion, one that obviously there will be disagreement with (especially from those who own
or operate “all kettlebell gyms”), kettlebells can be an enjoyable way to add variety and a bit
of fun to a workout. If a dumbbell press is a “good” exercise, a kettlebell press can be a
“good” exercise. The dumbbell is an obviously more effective and safer tool where either
implement can be used but I am not saying that “all kettlebell” training cannot be effective.
There are some true physical specimens, strong, enduring, and flexible who have done the
majority of their training with the ancient implements proving that but I would also quickly
contend that they would have done as well if not better with a more efficient tool.
Monster kettlebell
While this brief piece will set the internet chat boards buzzing and the new wave of fitness
entrepreneurs and strength gurus hollering, especially those tied to commercial interests that
sell kettlebells, kettlebell training courses, kettlebell seminars, and perhaps newly minted
kettlebell attire screaming in protest and pointing fingers in my direction while using phrases
like “know-nothing,” without the commercial and finance generated push kettlebell training
has received only since the mid-1990’s, these objects would still be no more than a footnote to
the history of the Iron Game. What some also don’t know is that dumbbells, like barbells and
plates, have varied in type, quality, construction, and ease of use since their introduction to the
strength and powerlifting world. As a footnote to this specific column it should be noted that
my lovely and insightful wife Kathy noted the same disadvantages of kettlebell training while
predicting it would “be the next big thing” in the commercial arena, way back in a 1987 issue
of our STEEL TIP NEWSLETTER thus the more things change, the more they remain the
same!
More Dumbbells
I could make the obvious joke and point out the knee jerk reaction of many in the strength
community who said, “Yeah, Dr. Ken wrote about dumbbells from a lot of self knowledge, he
is a dumbbell because of his adversity to kettlebells!” To me that would have been funny but
allow me to be brief and clear. There is nothing “wrong” or incorrect about doing any training
with kettlebells but it is not an efficient tool and for some applications not a safe tool relative
to the use of a dumbbell. Again, I will relate to the fact, and it certainly is an undeniable fact,
especially for those of us old enough to have lived through the so-called “Golden Age Of
Training” of the mid-1950’s to late ‘60’s, that you just never saw a kettlebell unless it was
stored in an elderly former lifter’s basement, or stuck in a corner at the local YMCA. I can
recall reading some of the 1961 and 1962 Weider magazines when he was selling “kettlebell
handles” that could be attached to one’s adjustable dumbbell bar.
The “science” behind the handles, and that’s a word not to be thrown around too seriously
when it comes to the Weider pronouncements and so-called “research” circa 1960’s, not when
the Weider Research Clinic was little more than a sign on a broom closet, was based on a
change in leverage that the handles would allow. This in turn would make the exercise more
effective. Well, if one makes a movement less efficient, yes, it can be construed as being more
difficult, especially if it drifts into the descriptive arena of “awkward” but even then, the
handles were a hard sell and had few takers. By the late 1960’s, the only kettlebell handle
offering made by Weider was as a pair of handles included as part of the “Superior Big 16”
barbell-dumbbell sets offered and the advertising line was “Kettlebell Set for broad, he-man
shoulders.” The “sell” was the suggestion to use the handles for lateral raises or front raises,
thus the reference to broad shoulders, as their use was otherwise limited. Eventually the
handles fell both out of use and the Weider catalogue of products. Dumbbells however, could
be found anywhere that weights were lifted, including the York Barbell Club where Olympic
weightlifting ruled the day.
Dumbbells, like barbells, have varied in materials, construction, quality, and shape throughout
their history. My wife disappeared for an hour or two on a Saturday afternoon this past fall
and excitingly returned to the house with the announcement that our neighborhood was
having three simultaneous garage sales within a few blocks of our home. This was not
thrilling news to me but I more or less humored her and asked what had been such an
“exciting” find. For the grand total of fifty cents, she had purchased a pair of wooden
dumbbells that she dug out of a pile of “stuff” and the owners were more than happy to see
the dumbbells leave their premises for that princely sum. My very intelligent and industrious
wife immediately fell into the research and her exciting find proved in fact to be just that: a
pair of wooden one pound dumbbells manufactured approximately ninety years ago by
Standard Narragansett Machine Company of Providence, Rhode Island. A great discovery and
an indication that from the first use of hand held weights or dumbbells, the materials used
were limited only by the availability of what was in the locale and the imagination of the user
or maker.
Although a number of lengthy treatises have been written about dumbbells and their origins, I
have no doubt that they have been manufactured or “home made” using wood, iron, stones,
cement, and possibly old cannon balls! If one looks at the mid to late 1940’s editions of
Strength And Health Magazine, large scale “weight training” was undertaken by the military
to hasten the troops’ preparation for entry into combat. They utilized what we might presently
term “circuit training” and had the troops in basic training doing barbell exercises with
“barbells” made from concrete filled soup cans that were attached to the ends of a length of
pipe. I am quite certain that photos could be found of hand-held weights/dumbbells made in
the same manner. I know that many of my early dumbbells were made in my father’s iron
shop from either scrap pieces of solid round stock or pipe to which I welded inside and
outside collars and the appropriate number of plates so that I had a rather extensive set of
permanent dumbbells.
For those who have in fact made their own dumbbells, it quickly becomes obvious that one
cannot “just make dumbbells” if they want to do so safely. The first order of business would
be to accumulate enough plates to make the neccessary number of dumbbells in the desired
denominations. From seventh grade onward, I became very proficient and persistent at
dogging the guys in school whom I knew lifted weights. The standard barbell and dumbbell
sets that were sold at local sporting goods stores and the occasionally stocked department
store consisted of a five foot bar, two short dumbbell bars, inside and outside screw-on collars
for the three bars, and enough plates to construct what was advertised as a “110 Pound Set.” It
usually did not take more than a month or two before the erstwhile Man Mountain Deans
would give up their quest for Herculean size and strength, and another few weeks past that
until they were ready to recoup some of the monetary investment they had put into their
barbell set. Usually these wound up under the bed, in the rear of a closet, or stuffed behind
other little used items in the garage or basement. I would volunteer to pay next to nothing
which was at least more than their perceived worth of the set at the moment, and most
importantly, remove the weights myself. On more than one occasion, I made an indelible
impression on the citizens of Point Lookout, Lido Beach, and Long Beach as I walked up to
two to three miles from the pick up point to my house, with the loaded bar held across my
back. With anywhere between 110 and 250 pounds I would traverse the distance to my home
gym, huffing and puffing the entire journey, but determined to “get the deal done.” There was
no way my working and disinterested parents were going to invest any time into my lifting
obsession, even when I toned down my involvement with the description of my twenty-four
hour per day “jones” as a hobby. Thus, I was left to my own devices, which was limited to
walking, to get to the site of purchase, and then get the merchandise back to the house. In
retrospect, in addition to providing entertainment and a certain amount of reinforcement that
“this boy is probably crazy” to the neighborhood, any lower body power later exhibited while
playing football, running sprints on the track team, or involvement with other physical activity
no doubt was positively influenced by what had to be dozens of trips of greater or lesser
distance to buy, transport, and then stock my home gym with discarded weights. It wasn’t
until I read a copy of the September-October 1963 edition of the original Iron Man Magazine
that I discovered the amazing story of Joe Reginer. Mr. Reginer had spent decades building
his own equipment, much of it from junk yard refuse he reconstructed into very useable,
functional equipment that was similar to many of the machines now seen in modern gyms. He
had over fifteen thousand pounds of plates and literally thousands of pounds of “stuff” that
resembled barbell plates or could be used for lifting purposes. When he moved from Chicago
to San Diego, his 7500 pounds of barbell plates wound up in Los Angeles.
The Iron Man article says it best so… “Since Joe did not own a car, he traveled to Los
Angeles each Saturday on the train, carrying two suitcases. These two suitcases were carried
back and forth to San Diego with a total of 250 lbs. of weights, 125 in each suitcase. Upon
arriving in San Diego, he would take a bus to his home and still have to carry them several
blocks up a hill to his house.”
The article noted that when much younger, he transported four 75 pound steel plates home on
a bus and with no seats available, had to stand and hold them the entire trip as they were so
cumbersome he did not believe he could pick them up once he placed them down again. This
was the same guy who while stationed on Okinawa during World War II made a 250 pound
barbell out of plywood. The only thing I could think of was “Unreal but this kind of thing
must have made him unbelievably strong” and the article written by Leo Stern as per the
observations made by him and Bill Pearl indicated that Mr. Reginer was indeed, strong! These
types of feats also made my piddling walks with up to two hundred pounds or so rather
“punky” by comparison.
Falling under the heading of “Its
tough work but someone has to
do it” a photo from
approximately 2001, Dr. Ken
spotting Summer Baskin. To
Summer’s credit, those 20 pound
York Hex Head Dumbbells
rather quickly became a lot
heavier as she trained for her
first strongman competition.
Summer’s brother Whit Baskin
was a top ranked strongman
competitor until injured and
comatose in December of 2000.
Summer decided to enter the
Northeast Strongman
Championships in Massachusetts
where Whit would be honored
and a fund raising donation
would be made. She made
amazing progress, became quite
strong and muscular and entered
a few contests over the next two
years. Her training, like that of
her world class brother,
consisted of conventional barbell
and dumbbell exercises and of
course, specific strongman
events.
The dumbbell deadlift is an example of this. Look through the last six issues of Powerlifting
USA Magazine. See how many times the dumbbell deadlift is utilized as a substitute for the
actual competitive deadlift during for instance, the off-season or as an assistance exercise.
Without taking the time to look myself, I would predict that you will not locate this exercise
within the magazine’s pages at all. Before one succumbs to the knee-jerk response that “If it
was any good, it would be used by good lifters” I would defy any aspiring lifter to actually do
the dumbbell deadlift hard, heavily, progressively, and consistently for six or eight weeks, and
then state that they did not feel they were working incredibly hard, did not enhance the
muscular size and/or strength of the involved musculature, or that it isn’t an effective exercise
“just to get stronger.” Remember the basis of strength or weight training for any athletic
activity; you are training in order to improve or enhance “the raw material” of the body, in
this case most obviously the muscular system. One then learns the skills of their athletic
activity and applies their enhanced strength to their skill development. This is how one’s
performance is improved, this is why an athlete trains. Powerlifting is a sport and in the same
manner as other sports, one trains to become muscularly larger, at least to the limits of their
weight class, and of course stronger. Confusion occurs because the sport itself utilizes the
barbell and consists of the performance of barbell movements in three specific planes of
motion. However, the philosophy is the same and in our specific example, using dumbbells
for the deadlift exercise can be and should be an experience that brings one close to their
physical and mental limits. Excluding technique or form as it applies to a competitive barbell
deadlift, the dumbbell version of this gives very intense work through a very complete range
of motion to the musculature involved with the competitive deadlift. Why then would this be
a negative? Yet, again allow me to ask where within the pages of PLUSA or other media
supplied training sources is this excellent exercise included?
With minimal information and directions, I recall going to a warehouse on Long Island where
I was told a group of competitive and non-competitive powerlifters were training for what
was then a nascent sport. On a Friday evening I drove alone into a rather isolated and desolate
industrial area and more or less looked around for any building that had a light shining
through a visible window. I was fortunate that it took no more than three or four tries until I
located the correct door and was able to enter a stark room consisting of what was some sort
of machine shop on one side and a very basic but complete gym on the other.
The late Ray Rigby squats
826 in one of Dr. Ken’s
home gyms: a squat rack,
bench, plywood for a
platform, homemade
dumbbells, and lots of
plates
My presence was immediately noticed but not acknowledged and not one word was said to
me. I sat in a corner and spent perhaps two hours watching a dozen very strong and serious
men throw an awful lot of weight around and it was impressive. African American and
Caucasian, the mixed group was familiar and easy going with each other but I had no doubt
they could clear any bar in short order had they been offended or otherwise angered. Only
when they were done, was I approached and asked if I could be helped in any way.
Obviously, having sat still in a corner for approximately two hours doing nothing else but
observing and mentally taking notes on everything I saw, marked me as someone seeking
information on what they were doing.
Home gym garage in Valley
Stream, NY, a 25 year
endeavor complete with
Sutherland electric squat
rack, power rack,
dumbbells, and lots of
plates and little more.
This was typical, at least for me and it brought me to the known New York City area training
sites like Mid City Gym when it was on Times Square, the rear of Leroy Colbert’s health food
store on 84th Street and Broadway, the loft above Jack Meniero’s Mr. V Sport Shop in
Brooklyn where I saw Larry Powers, Freddy Ortiz, and other monster bodybuilders lifting
rather impressive amounts of weight, the Olympic Health Club in Hicksville that featured the
training exploits of discus throwing champion Al Oerter, and any countless number of
unmarked storefronts and industrial spaces used for lifting weights. The most impressive
memory I have of the warehouse visit noted above was the fact that there were loaded barbells
on numerous racks and lined up in a semblance of order all over the concrete floor. As the
introduction of rubber bumper plates was still years away, there were some heavy duty
welcome-type mats scattered around to offer minimal cushion to the impact of the forty-five
pound Olympic barbell plates when the bars were brought to the floor but I did not believe
they did much to protect the bar, plates, or concrete. That they had what must have been a
dozen bars all loaded to a different “base weight” so that for example, deadlifts being done
between 225 and 315 were completed on one bar, those between 315 and 405 on another bar,
and any amount between 405 and 495 and up on yet another bar was, to me, just the coolest
thing I had seen to that point in time in a gym setting. Two or three benches and an incline
bench as well as three squat racks all had their own Olympic or standard bars and all had
“base weight” that never went below a specified amount. This made group lifting as quick,
efficient, and exciting as it could be and it became a goal of mine to have a private or public
training facility that boasted a set-up where there was an abundance of bars and plates.
Additionally, this particular warehouse gym also had many home made dumbbells lined up on
the floor against one wall.
1996 Olympic gold medal
winner Derrick Adkins
squats in barest of home
gym set-ups, just the
squat/pull/press rack circa
1975 Dr. Ken welded for
the Malverne High School
weight room, rescued and
resurrected at time of
school renovation.
Before hex-head, urethane covered, or any other type of commercial dumbbell, there were
either the so-called “gym dumbbells” made from a specific company’s plates that were
welded onto short “dumbbell bars” or there were the large, round, globe-head dumbbells
made by York and only a few other companies. Certainly there were other brands such as
Jackson Barbell that made dumbbells but the two usual types encountered in the few
commercial gyms or health spas of the day were constructed of standard plates or the casted,
large globes. As was the standard of the day, all of the dumbbells I noted in the warehouse
gym that impressed me so much, were constructed of small, one-inch holed plates that were
attached to appropriately cut and measured short bars. This was the purpose in my own quest
to gather and save as many of the unused 110 pound barbell sets that friends and schoolmates
stashed beneath their beds or in the back of their closets after minimal use. Most of the
fellows who made their own dumbbells obviously first used the dumbbell bars provided with
any barbell-dumbbell set they had purchased. When it came time to get serious and make an
entire set of dumbbells or at least enough so that any workout could flow without the
interruption made necessary from stopping to change the weight on any dumbbell, one had to
first get the bars to place the weights upon. Having access to my father’s iron shop made this
easy for me. Typically, any inventory in the typical “mom and pop” iron shop will be hot
rolled rather than cold rolled. For the sake of simplicity, at least for this specific point, hot
rolled steel or iron is reshaped at a temperature above what is termed the re-crystallization
temperature, which will cause the molecular structure to alter and align differently than the
starting product. Cold rolled is done below this temperature and is much stronger when
finished relative to hot rolled bars. Hot rolled is fine for dumbbell bars but anyone who has
lifted more than 150 pounds on a length that is in excess of five or six foot, as per a standard
Olympic barbell, has discovered the hard way that it doesn’t take much force or loaded weight
to bend these bars. All of the barbell stock used is cold rolled and further treated to make for
example, any of the top name Olympic or power bars extremely strong and resistant to
damage. Obviously, having gathered an inventory of short bars, one can then consider the
actual construction of their dumbbells but if they are to be strong and not break apart when
dropped more than a few times, some special care needs to be taken when welding them and
then there is the matter of the dreaded “rotating sleeve.”
Before getting into the construction of home made dumbbells and discussing the archaic
“revolving sleeves” that were part and parcel of every 110 pound set of standard weights sold
throughout the 1950’s and ‘60’s, I want to present an e mail from Jan Dellinger. For those
who don’t know, Jan was York Barbell Company’s representative from approximately 1976
into the early 2000’s. He probably held every job the company had to offer but after John
Grimek retired, was best known for being the one guy in the office who could actually answer
lifting related questions. He remains one of the true historians of all aspects of the Iron Sports
and as the one person who worked side by side with the great Grimek, has all of the behind-
the-scenes stories. From Jan with my comments, below:
Beyond being a recycled sales gimmick, I never quite got the latter day fascination with
kettlebells. Although I have to admit that once the weight room of the school where I work
purchased a few moderate-weight pairs of K-bells, I had to do a bit of overhead pressing
and curling with the nostalgic apparatus, mostly to say that I played with them a little.
Oddly, I much prefer the swing movement with a dumbbell.
Your mention of the cast iron kettlebell handles from Weider ads of long ago brought back
a number of memories. One was that Joe's sales pitch for them was right out of George
Jowett's mags, or more specifically his shoulder booklet course. This is not just Joe-
bashing as York ads from the late '30s or so did the same, and seemingly copied the
graphics from said Jowett booklet for inclusion in their ads. Thus making it clear of course,
that nothing in weight training is new, nor was it even decades ago.
Pipe and plate dumbbells, huh! Alan Calvert's Milo Barbell Company offered pipe and
plate sets in the early 20th Century, which were billed as an "economy set" as compared to
ones which featured a solid steel bar. Allow me to repeat the comment from above, “Thus
making it clear of course, that nothing in weight training is new, nor was it even decades
ago.”
Of course, I learned along the way that kettlebell handles do not have to be cast iron.
During my years at York Barbell, basement inventors--"reinventors" in most cases--would
send us samples of things they hoped would strike our fancy sufficiently to want to market
them. Sometime in the 1980s, someone sent us kettlebell handles made from PVC pipe and
glued together. For their intended use they were just fine. In fact, I still have them in my
basement, although I run an 18-inch long steel bar thru them and practice one-hand
deadlifts, using them as the handle. I've been waiting for the glue to dry out and the thing
to break or bend, but so far they have stood up to 250 pounds. I wish I was younger and
stronger as I would like to see at what poundage they start to give.
Among the things the late (and very great) Vic Boff tried to impress on me about the
training habits of his generation, or maybe it was the one before, was their ingenuity at
improvisation. Basically, making what they had at their disposal work over the long haul.
Found a great example of this 10 or 11 years ago in the Philly warehouse of handbalancing
great Robert Jones, who was very identified with Milo Barbell and was a confidant of
BoHo's (Bob Hoffman) for years after he bought out Milo.
Sorry to drone on. Just wanted to offer some positive commentary about your dumbbell
installments.
Jan
Jones had a 15 or 20-pound solid dumbbell which he made adjustable weight-wise by boring a
hole in each end and threading the inside of the holes to accept a standard 5/8" bolt. Hence,
one could bolt extra plates onto the ends of the solid dumbbell to increase the resistance in
relative safety...at least by the legal standards of the day. At least, a home trainee did not have
to invest in a slew of solid dumbbells.
Another photo of the
wonderful old wooden
dumbbells located at a
garage sale by Kathy
In addition to the many short pieces of one-inch hot rolled stock I would cut in my father’s
shop for my various dumbbell construction projects, I would on occasion find myself with the
numerous five-foot bars that the standard 110 pound sets came with. In time, as I collected the
unused, little used, or about-to-be-discarded sets of various friends, classmates, or less than
committed trainees I would hear about, I would have a collection of potentially unused
lengths of iron. Some were of better quality than others but all were 1/16th to 1/8th of an inch,
thicker than the round stock in my father’s inventory. Over time, I found that the thicker
diameter bars were much more suitable than the one-inch round stock for the larger
dumbbells, arbitrarily anything over 100 pounds. The thicker bar was a bit easier to control
and the increase in diameter, no matter how seemingly minor, better dissipated the force of
that heavy dumbbell as it was held throughout the course of a set. If one examines the higher
quality dumbbell and fixed barbell offerings from companies such as Ivanko Barbell in San
Pedro, California, it can be quickly discerned that they offer a thicker handle for fixed
barbells, EZ Curl type of bars, and dumbbell sets. This is done specifically to allow for this
more efficient force distribution in one’s hand and safer execution of the exercise. When
Kathy and I opened our Iron Island Gym on February 3, 1992, we offered three full sets of
dumbbells. Our primary set of dumbbells, from Ivanko, went from 5 pounds to 55 pounds in
two-and-one-half-pound increments, then to 200 pounds in five pound increments. All of the
dumbbells from 100 to 200 pounds had slightly thicker handles, not to offer “more grip work”
for our trainees, but rather to offer better control and more comfort. Our fixed Ivanko barbells
and fixed EZ Curl bars also followed suit with everything over 100 pounds set onto one-and-
one-quarter-inch diameter bars. This made a noticeable difference when handling heavy
weights and my early dumbbell construction dictated these equipment decisions for the gym.
Wisconsin strongman and
chef extraordinaire Tony
Scrivens farmers walk, a
great “finisher” or primary
exercise that can also be
done with heavy dumbbells
In last month’s column I noted that every barbell set manufacturer offered a “rotating sleeve”
on either their barbell and/or dumbbells. As a reminder to the younger generation(s) of lifters
reading this, powerlifting was not a formal, organized sport with any type of national
championship until 1964. Olympic weightlifting was the only “legitimate” lifting sport with
bodybuilding seen as a non-athletic event fraught with the myths of numerous social ills and
evils. Thus, the inclusion of Olympic lifts and “Olympic type” of lifting or exercise
movements was seen as necessary in any course of training instruction. Your standard “basic
program,” “beginner’s, intermediate, or advanced programs” always displayed a clean, clean
and press, push press, jerk, or snatch as part and parcel of the overall course of instruction.
With the focus upon selling more inventory, both Hoffman and Weider, even for their strictly
bodybuilding courses, included these basic, multi-joint, Olympic weightlifting or
weightlifting themed movements within the body of the instructional materials. On a non-
rotating 1-1/16” bar, many of the exercises could be painful or destructive to the wrists and/or
elbows. Though I doubt that safety was an issue or within the consciousness of either Bob or
Joe when it came to making money, a rotating sleeve placed over the shaft of the bar did in
fact make the Olympic lifting type of movements safer. Thus, included in the standard barbell
set, the rotating chrome sleeve, flimsy and absent of anything such as bearings that might
have made rotation of the bar smoother, still improved the bar movement in the trainee’s
hands. Without a sleeve and with heavy weight on the barbell, the trainee would have to
literally open the hands a bit when cleaning the weight from the floor to the shoulders.
In 1963, the Iron Man
rotating sleeve for the
standard barbell set would
cost an additional $.3.30!
This action would allow the non-rotating bar to roll in the hands enough to “catch” it at the
top of the movement and avoid the physics-determined tug and pull on the wrists once the
barbell came to what amounted to a screeching halt at one’s shoulders. The sleeve was a
chromed tube that slipped over the five or six foot length of one-inch bar, and was secured by
the inside collars that would be placed upon the bar after centering the rotating sleeve. The
bar-within-a-tube had enough clearance to allow for the barbell to spin enough to make one
think they were “almost lifting on a sort-of-real Olympic barbell.” Of course, for any trainee
that had actually lifted on a “real” Olympic barbell, the action wasn’t close! However,
whatever “give” was available due to the presence of the rotating sleeve gave a safer option
than going with the bare bar. Of course the thin-walled tube often became distorted with even
moderate use and the threat of a “short stop” as the bar’s rotation picked up momentum
always existed.
The short length dumbbell bars also were provided with a shorter, chromed tube that allowed
the dumbbells to rotate, at least a bit. The unintended advantage of the tube or sleeve was the
added thickness these provided to the dumbbell bar, placing more stress upon the grip. That
was perhaps the only positive of its presence. Anyone who has used a “solid” dumbbell or
“gym” dumbbell where barbell plates are placed upon the dumbbell bar’s shaft and secured
with an end cap and a variety of bolt or screw devices knows that a rotating sleeve on a
dumbbell bar is not really a necessity. One could argue the case for the longer barbell as the
aforementioned paragraph notes but few dumbbell movements are done where a rotating
sleeve is necessary. Far more important for dumbbells, especially very heavy dumbbells, is a
means of securing the plates to the bar.
Welding cast iron plates to “regular” iron bars presents some unique problems or conditions
and I would like to convey this to our Titan Support System readers. My comments, made
after discussion with Tom Ryan, an architectural blacksmith that works in my brother’s
Koenig Iron Works shop in Long Island City, N.Y., are general in nature and as Tom pointed
out “The final options are based upon the exact conditions of what one is welding and how it
will be used.” Tom, like my grandfather who as a young boy began his life’s work as a
blacksmith in Poland, does things the correct way.
Let me first state that cast iron isn’t used and should not be used to carry a load as one would
in using a piece of beam. Cast iron can be used as a column as the stress/force is in
compression, but it’s too brittle to load as per beam use and can fail. To emphasize its
brittleness, I did my training at Malverne High School when I taught and coached there. We
did not have a wrestling team when I arrived at the high school but there was what had been
the former “wrestling room,” a space the size of three large closets jammed together with half
of the floor covered by Resilite mats. The mats, a huge jump forward from the canvas covered
horsehair mats that had been the standard previously, are still made by the Resilite company.
These were manufactured specifically for wrestling and I can recall the advertising they used
that showed an egg being dropped from a rather significant height onto the mat, without
breaking or damaging the egg in any way. They were not too thick, yet they were force
absorbent. I rearranged some of these so that the underlying wooden floor served as my
“lifting platform” footing, while the mats were used to “catch” the barbell plates when the bar
was returned to the floor. During one workout I tossed a York two-and-one-half-pound plate
to the cross countery coach who served as a training partner during that year. He fumbled the
plate, it hit the mat, and cracked in half. We were amazed that a top of the line York Olympic
plate would so easily split in two. I sent the pieces to John Terpak, the President of York
Barbell Company and he indicated that if the plates “hit just right” they could, due to their
brittleness, crack. It was a lifelong lesson in cast iron dynamics for me. Even those with some
welding experience will have to practice and follow procedure to make safe dumbbells one
can have confidence in using, or there is a probability that the welds could, or will crack or
split. Many experienced welders will look at my recommendations and no doubt state, “Geez,
you don’t have to do all of that, its easier and faster to…” but I want to give general
recommendations that make for a safe finished product.
In the photo above, we have pictured one not-so-strong older guy standing with two very
strong individuals. George Kasimatis is currently the head football coach at Long Island’s
Sewanhaka High School. For die hard football fans, Sewanhaka was the high school of former
University Of Miami and long time professional quarterback Vinnie Testaverde and George
has done a wonderful job of utilizing strength training as an integral part of their success the
past few seasons. George as a younger man, was a terrific collegiate fullback and competitive
powerlifter, certainly one of the strongest pound-for-pound lifters Long Island has ever seen.
“Tommy O” was legendary for a number of things, including his skills as a bouncer and he
parlayed his education, football ability, and physical strength into a position as a New York
City Court Officer. Television addicts will recognize him as the court officer on the long
running Judge Hatchett television show and frequent guest on “World’s Dumbest Criminals”
type of episodes. Like George, Tommy represents the adage I have frequently used in print
and in lectures that “The strongest man in the world probably isn’t lifting at the Olympics or
winning the Senior National Powerlifting Championships. Instead he’s working a full time
job, has family responsibilities, and training by himself in a garage somewhere in Cleveland,”
the point being that like these two men, there are an awful lot of unbelievably strong
individuals walking around that the general public doesn’t know about. That said, note the
Olympic barbell plates they are holding. I had a penchant for welding handles on a lot of
different odd objects, including barbell plates so that they could be carried around for strength
and cardiovascular type of work. This is another application of welding iron to cast iron as the
handles would either be round stock that varied in diameter from one-inch to two-inches, or
pipe with similar dimensions. The preparation and welding procedures as outlined within this
article were the same for these iron handles. After being bent to shape they would then have
to be welded to the cast iron barbell plates. These made excellent “Husafelt Stone type” of
carrying objects that served as effective finishers to many workouts.
Like any other welding job, insure that the rod and plates are clean and free of visible grime
or grease. An oven cleaner or degreaser works and there are products sold in automotive
stores that will take leaking oil and grease off of your concrete driveway. These will do the
job for your dumbbell project. I once degreased one of the engine blocks I planned to use for
some “strongman” and lifting activities with a can of Easy Off Oven Cleaner and my garden
hose and it worked perfectly. It usually isn’t necessary to bevel the metal with a grinder for
this specific dumbbell application but pre-heating all of the round stock and cast iron plates is
recommended. Using what is now referred to as “old fashioned” stick welding rods, and I
returned to school and was no longer working as a full time iron worker when wire and gas
welding was first being introduced, often does not call for pre-heating but I think it helps
make a better weld. We always used a torch to about 500 degrees F if welding steel to cast
iron. Weld, brush the slag from the hot weld bead, and using a light round- head hammer,
peen with light and fast blows. This hot-peening reduces the weld stresses and adds strength
to the weld, increasing resistance to cracking. Welding will involve the last plate that is placed
on the round stock and if used, a large steel washer. That end-of-the-line plate should be
welded to the round stock and the washer if used, should be welded to both the cast iron plate
and the round stock handle. Once the welding is completed cool the cast iron at a slow,
controlled rate, as slowly as possible. This usually isn’t done, with the completed dumbbell
most often left sitting on the welding table until its cool enough to handle. Take the time to
cover the dumbbell(s) with a welding blanket. If welding a large number of dumbbells or an
entire set, you can cover them with hot ash or sand, but use something to insulate the welded
cast iron from the cooling air. As Tom said to me, “the slower the better” so as one might
guess, if we’re attempting to slow down the cooling off process and cover properly, the metal
will remain hot for a day or even longer. Again, I will repeat that this is almost never done
and when younger, I certainly never approached the “cooling off period” with any sense of
patience or seriousness. I believed that if I had welded properly, the specific weld would
“hold” and there were times that I was attempting to use the dumbbell in training almost
immediately afterwards while the cast iron was still hot.
As a “stick welder” often at the short end of the humorous comments about being “a really old
guy” or a very “old school iron worker,” I asked Tom about options beyond my knowledge or
day to day experience. Brazing with a brass rod and oxy-acetylene provides a very strong
weld if one does not have the appropriate/proper welding equipment. Pre-heating to 1100
degrees F (think “red heat”) should be done. Tom believes that stick welding is the most
likely to crack if for example, 150 pound dumbbells are tossed to the ground as they usually
are in most training facilities but it’s the easiest welding option if done correctly. He noted
that “if using Ni Rods, make short one-inch welds” and of course, this would be my option as
a “pre-wire and gas guy.” For those seeking to make their own dumbbells using what many
consider to be archaic methodology, one recommendation is:
TIG welding:
Typical Applications:
Royal 44-30 is excellent for making repairs on all ductile and malleable irons. Royal 44-30 is
also useful for the welding of other high-strength nodular and gray cast irons where maximum
strength and ductility are required.
(My comment: For a heavy dumbbell that will be dropped during heavy lifting sessions,
strength of weld would be the key goal and application).
The addition of manganese provides superior wetting and crack- resistant weldability on even
the most difficult cast iron applications. The Royal 44-30 is also used for surfacing to
improve wear resistance or for buildup. Also best for welding steel or stainless steel to cast
iron.
SPOOL WIRE:
For cast iron, cast iron steel, high
PALCO 808
strength, non-cracking
I am hopeful that this information will be useful to those who have an interest in putting
together their own dumbbells. Remember, in “my day” you couldn’t walk into a local fitness
type of store, department or large sporting goods store and purchase a set of dumbbells. Now,
there are choices of hex head, hex head covered with urethane, “gym dumbbells” made with
standard plates with or without a urethane covering, with many other options. If you wanted
“pre-made” dumbbells you had to locate York Barbell Company or Jackson casted dumbbells,
referred to as “solid dumbbells” or construct your own. Homemade dumbbells have a great
look and to me, a great feel. That each one may have a bit of a different feel because a
different diameter handle might have been used and/or a different brand of plate just adds to
the enjoyment of training. I know in my own case, it sets me back into my earliest training
days, reminding me of the enjoyment I had then and still have when I train.