Olympic Barbell Collar

PRINT, ASSEMBLE, and USE AT YOUR OWN RISK

Barbell collars can be cheap or expensive…  I figured I could make custom ones for 3D printing gym enthusiasts!

Two sizes are available in the zip folders:

• Ø2" will fit slightly loose on Olympic sleeves and will almost certainly require the adhesive foam.
• Ø50mm will fit snug, but you may want to attach adhesive foam.  I haven't used adhesive foam on this one, but I recommend trying a thinner foam than 5mm suggested below.

This assembly uses M3 and M5 screws and nuts:

*I used weather strip sealing foam like you'd tape around a window https://www.amazon.com/dp/B07L6L1BML?psc=1&ref=ppx_yo2ov_dt_b_product_details

Assembly:

1. Press-fit insert all three (3) M5 nuts into the sunken hex holes on the two (2) large crescent-shaped collars.
2. Press-fit insert all five (5) M3 nuts into the sunken hex holes on the same side of the large collar.  (This will ensure the bolt heads are all on the same side of the collar)
3. On the two (2) large crescent-shaped pieces of the collar that do not have hex nuts, place all of the M3 and M5 bolts in the holes they respectively fit in.
4. Slide each of the small, middle collar sections onto the bolts.  The divots cut into the sides of the small pieces should mate and make a 10mm wide slot to put adhesive foam in (see optional step below).
   • NOTE:  Make sure to place the piece shaped like a dolphin tail between the two small crescent pieces that have an arcing slot “milled” into them…  the dolphin-tail piece's curling tail should form a friction-fit clasp over the opposite end of the slotted pieces
   • NOTE:  all of the radii around the outside should match up visually
5. Assemble the crescent pieces you press-fit the nuts into in step #1 and step #2.
6. Once the final pieces is assembled, screw the bolts into the nuts.
7. If all went well, your collar should look like one of the attached photos.  The “dolphin tail” should latch around the slotted pieces' radius.
8. (Optional) To help the collar tightly squeeze the barbell sleeve, you can add adhesive foam.  I recommend cutting 10mm wide x 5mm thick foam to two (2) lengths about 10-15mm each.  Tape these in the divots inside the middle circumference of the collar.

PRINT, ASSEMBLE, and USE AT YOUR OWN RISK

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