I'm not a regular poster here but do lurk alot. This year I decided to trash the gym membership and build a home gym in the basement. A power rack was in order but cash was tight so I built my own. I use AutoCAD daily for my job so I drew up a plan and thought it may be helpful for some of you here. While I have not officially "tested" the rack by purposely dropping a huge ass weight on it, I have no doubts the frame will take a serious beating...it's alot of lumber! It's more solid than some steel cages I've seen.
Everything to build this cost me $115 in materials you can buy at Lowes or Home Depot. It's mostly 2x6 boards with some 3/4" diameter plumbing pipe and fittings used for the rack pins and spotter bars. Word of advice: buy the better grade lumber for the vertical legs at the very minimum...sorting thru the cheap **** to find 8 decently straight board may take all day. Also the job does require some power tools. You will need a powerful corded drill with a spade or auger bit and ideally a bench mounted table saw for straight cuts. The holes to cut in the vertical legs is the most time consuming part of the project. Here's where you need the big corded drill as it will tear a cordless drill up in no time using the big spade bits. Overall expect about 3-6 hours of time depending on your construction skills. If you got any questions let me know, I'll be happy to help.
Below is a link to the plans as high resolution JPGS, this site won't let me post files big enough to read. The drawings are to scale if you print the page at full size of 11x17