My power rack design uses a crossbar shown here. The combination of a 3" separation between the holes on the vertical columns with 2" for the crossbar lets the pin control the crossbar height to a resolution of 1".Other design notes:
1. Hard nylon trim on the edges help it slide a little better and some heavy leather on the top of the bars serves to tone down the clanging.
2. The purpose of 1" steel pins to support the crossbeam was originally to allow using an steel bar instead of the
crossbeam. I never used that and if I were to make another rack, the holes and pins would be much smaller. Machining large holes is a bit of a bear without special equipment. On the other hand I'm real happy with it the way it is.3. I make no claims to the strength of this design. It seems fine to me but if you lift a lot of weight you should get an engineering analysis including the effects of the welding, and steel tube wall thickness.
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