Detailed Assembly

Kettlestack assembly involves bolting a handle onto a stack of weights (pic on right of "wings" surrounding a core).
Since most kettlebell motions are functional and engage multiple body parts, you won't find a need for repeated, small adjustments that folks expect with adjustable dumbbells.

(Click the pair to your left, or HERE for our video!!)





BTW, the key to the one/two bolt choice is the fact that there's a flange welded to one side of the hexaxle.

The easy two-phase assembly,
along with the Kettlestack's unique quickchange feature conveniently provides a wide range of weights .





STEPS:
1: group the center core
2: slide the bands over the core
3: slide axle through the arms and the core
4: tighten the right wing with the right
5: if(1bolt) tighten the left wing against the axle flange w/left bolt (there's no need to tighten the bolt's past snug).

The major points on Kettlestack assembly include:

1. deciding which weight to setup-Start with a weight you can curl- you can change it later.
2. deciding on one-bolt or two-bolt setups.
3. setting the correct core width and taper
4. getting a nice shape.
* Our front page isn't staged or contrived- wonderfully comfortable shapes in about a minute; T his shape flexibility is a basic part of the Kettlestack design.
* However, we cannot assemble your Kettlestack for you; Please follow the instructions (email us if you get stuck) and you'll have a nice, round Kettlestack that's functionally equivalent to a cast KB for snatches,presses and cleans.

One/Two Bolts ?

The kettlestack axle allows you to build either one-bolt(narrow) or two-bolt (wide) setups. You can see (right) that at a stack width of between 6" and 7" you have the option of going either way.

A good Kettlestack shape (somewhere between a sphere and rugby football) is going to be at least as wide as it is tall- you shouldn't use a pair of 10's to make a 20lb Kstack. The simpler one-bolt is for the narrower,lighter setups below 35 lbs, while the more flexible two-bolt is required (a safe amount of bolt overlap) for heavier stacks over 40lbs or 7" in width.



Core Width and Taper:


The Kettlestack has a  "flexomatic" geometry that allows the bands to
accomodate a range of core widths- anywhere between 3.25" and 4.5" or
between 3 and 5 plates in between the bands.*

With
one-bolt it's all in one shot- even if there are plates outboard of the
bands (see 25lber in table).  In a two-bolt setup (see top right
picture) the core and right wing are bolted together with the right
bolt, and the left bolt attaches the left wing.  On the right, is a
table  of the common comfortable shape setups.

symbol

|

Q

P

5

Z

A

description

support band

1.25lbs

2.5lbs

5 lbs

7.5lbs

10lbs

*
Don't try to wedge too wide a core in between the bands, just place the
extra plates on the outside of the bands.

weight

setup

notes

20

   P | 5 5 5 | P

narrow core setup

20

| P 5 5 5 P |

 

 25

P  | 5 5 5 5 | P

one bolt

32.5

Q P | 5 5 5 5 5 | P Q

one bolt

35

P 5 | 5 5 5 5 | 5 P

one or two bolts

37

P Q | 5 Z Z Z 5 | P Q

two bolts

45

Q 5 | Z Z Z Z | 5 Q

two bolts

45

Q 5 | A A A | 5 Q

stubby york style 10lbers

50

Q 5 | Z A A Z | 5 Q

two bolts

55

Q 5 | A A A A | 5 Q

two bolts

55

5 | Z A A A Z | 5

two bolts

70

Q 5 Z | A A A A | Z 5 Q

two 4" bolts

75

Q 5 A | A A A A | A 5 Q

"

80

Q 5 Z | A A A A A | Z 5 Q

 

80

5 A | A A A A A | A 5

"

85

Z A | A A A A A | A Z 

"

90

5 A A | A A A A | A A 5 

"

we'll be adding picture links to this table shortly........




You now have a fully functioning Kettlestack that probably looks something like the picture on the left. There is nothing between you and a great workout. Even so you, you might want to learn how to achieve a shape similar to the rounded ones (right).





The overall approach is simple: if a plate's edge sticks out enough to dig in, loosen the plates and push the offending high point flush or slightly below it's neighbors.

On the right is a photo of two nominal 55lb setups that have been shifted to remove the edge; The left setup has three 10s, and a pair of 7.5,5 lb plates, while the right has four 10s, and a pair of 5, and 2.5 lb plates. Note:

* The forearm would touch about 3 plates (5,7.5 and outer 10 lb) if it was resting diagonally across the plates (a typical GS setup)
* The plates have been shifted-see how the front profile has been rounded at the expense of the back profile.

As in the video (right), to form the shape,loosen the bolts, let the plates "sag" into a common kitchen bowl and retighten. That's it! about 30 seconds.Note that since the handle is touching the ground (watch the video), the bowl is rounding out the "patch" of the Kettlestack that the forearm will touch.


On the right is a photo of two nominal 55lb setups that have been shifted to remove the edge; The left setup has three 10s, and a pair of 7.5,5 lb plates, while the right has four 10s, and a pair of 5, and 2.5 lb plates. Note:

* The forearm would touch about 3 plates (5,7.5 and outer 10 lb) if it was resting diagonally across the plates (a typical GS setup)
* The plates have been shifted-see how the front profile has been rounded at the expense of the back profile.

Review of how to make a nice, round Kettlestack:

1. The slack between axle and holes lets you tweak the shape.
2. The right set of tapered plates (possibly including the 7.5lb plates) makes it very easy to get the desired shape)
3. You can easily remove edges with the "bowl trick" or equivalent.

If you have any Qs, please email us and thanks for reading.