DIY Push / Pull Workout Sled: Build Your Own Low-Cost Version

Many MTNTOUGHers ask how to substitute a sled when access to a gym or commercial sled is limited. Here’s how to build a low-cost, DIY push sled that works on concrete, grass, or turf, so you can add sled pushes to your training regimen.

This sled is durable, versatile, and ready to be loaded with sandbags, a cooler full of weights, or anything suitable you have on hand. Follow these step-by-step instructions to build your sled. Download the full materials and cut list here. 

Gather Materials

Most of these parts should be available at your local hardware store, and the total cost for building this sled was just under $100. For comparison, most retail sleds start around $300. You’ll also need some basic tools: a saw (circular, miter, or table saw), drill, wrench, and other common workshop tools.

Wood

• 1 × 2x4 (main skids/base runners; cut to 40" each, angled ends)
• 2 × 2x6s (platform/support structure and push wall; cut into seven 20" pieces and two 15.5" pieces)

Skate Surface

• Synthetic decking (like Trex or similar composite material) – ripped in half and angled for smooth sliding.

Push Handles – Optional

• Rigid EMT conduit pipe (1.5"–2" diameter; two handles at ~40")

Attachment for Pulling

• D-ring (or similar attachment point, called “D-loop”)
• 12-foot tow strap for pulling

Fasteners

• 4 × 4" carriage bolts + matching nuts and washers
• 4 × 5" lag screws (for push wall)
• 2.5" construction screws (for tacking/assembly)

Step 1: Cut the Lumber & Assemble Base

Make sure you cut your skids and base runners at an angle on both ends—ours were cut at about 25 degrees. This simple step helps the sled glide smoothly across surfaces and prevents hard stops if you hit cracks, bumps, or uneven terrain. Properly angled skids make your pushes more consistent and reduce the risk of the sled catching or tipping during training.

Skids / Base Runners (2x4)

• 2 pieces at 40" each
• Bevel the front ends (optional rear bevel) for easier sliding.

Support Pieces / Cross Braces / Platform (2x6s)

• 7 pieces at 20" each
• 2 pieces at 15.5" each

Step 2: Build the Push Wall

The push wall is optional, but we like using it because it places your body in a more ergonomic position during pushes. To build it, you will need the two 15.5" 2x6s and one 20" 2x6 from your cut pieces. We used a drill press for precision, but a cordless drill will work perfectly fine for this step as well.

1. Stack and attach the 2x6 boards for the push wall.
2. Drill 1.5" holes for the EMT pipe handles using a hole saw.
3. Attach a D-ring or “D-loop” at the front of the sled.
4. Connect a tow strap for pulling exercises or added resistance.

Step 3: Attach the Push Wall

We want to make sure this wall is very securely attached to the sled. Ensure the wall is solid and square before fully tightening, and keep in mind that additional lag screws may be required to achieve the desired attachment and maximum stability.

1. Secure the wall to the sled base with 5" lag screws, ensuring it is solid and square.
2. If necessary, ream out the 1.5" holes slightly to allow the push bars to slide cleanly into place.

Step 4: Carriage Bolts

This step will make your sled more rigid under heavy loads. Install carriage bolts to reinforce the structure—one in each corner should do the trick, but feel free to add additional bolts through the other slats if needed for extra strength and stability.

1. Pre-drill the holes to match your bolt size.
2. Position the head of the bolt toward the ground.
3. Use washers and nuts on the top side to secure everything tightly.

Step 5: Build the Skates

These are important because they allow your sled to easily glide on many surfaces without causing damage. Over time, the skates will wear down, but they are easy and inexpensive to replace.

1. Cut your skates to approximately 40"..
2. Cut all ends at a 25-degree angle to allow for easier pushing.
3. Countersink your 2.5" screws to prevent scratches or damage to your push surface.

Step 6: Cut & Install Push Bars (Optional)

Copy

1. Insert the EMT conduit pipes into the drilled holes.
2. File and smooth ends for safety.
3. Handles can be angled or positioned as you prefer.

Step 7: Install Pull Strap

We used a standard tow strap because it has two built-in handles. We chose the 12' version so you have one handle in each hand (approximately 6' per side), which works well for most users.

Step 8: Load and Train

Optional Loading Materials

One of the best things about this DIY sled is its versatility—you can haul just about anything on it. We know not everyone has a Yeti cooler, and that’s totally fine. Sandbags, dumbbells, rocks, or any heavy, stable object will work perfectly. We’ve even tested the sled loaded up to 350 pounds on asphalt, and it handled the weight smoothly, giving you plenty of options for resistance-based training at home or outside.

• Place a cooler, sandbags, rocks, or dumbbells on the platform for resistance.
• Test the sled on concrete, grass, or turf and adjust the bevel of the skids if needed for better sliding.

Final Tips

• Ensure all screws and bolts are tight before each session.
• Regularly check handles for wear and smooth out rough or sharp edges as needed.
• Adjust the amount of weight on your sled to meet your training goals.

Disclaimer: This DIY push sled involves the use of power tools and heavy materials. Always follow proper safety precautions when cutting, drilling, or assembling wood and metal components. When training, ensure proper form and technique to avoid injury, and consult a fitness professional if you are new to sled pushes or resistance training. Use the sled at your own risk.