http://fitdadchris.com/blog/wooden-power-rack/ Hey so this is not step by step, but gives you a good idea on what I did and how you can use the same thing. I love to help so leave a comment or ask a question. This will give you some ideas if you are looking into building your own. Check here for how I put together the support beams http://www.youtube.com/watch?v=_IwNtyI7gp4
How was this design tested to be certain it can hold at least 550 lb? Anything that is listed with a maximum load limit should actually be able to hold at least twice that amount before it breaks. If this breaks at 550 pounds it is only rated at 275 or less. Just trying to be certain you actually thought about this before telling the world to go ahead and build it.
I used your idea for bar holders on my rack, but instead of using regular 45-degree elbows (threaded female on both ends) with a close nipple and end cap, I used a 45-degree "Street Elbow," which is threaded female on one end and threaded male on the other. Since the street elbow is one piece, the transition in shape from the elbow to its threaded nipple is tapered instead of stepped, and it makes unracking the barbell quite a bit smoother. I also ended up removing my end caps, the street elbow by itself is enough to safely hold the bar, and leaving the caps off also help in unracking.
At least not safely. Drilling a hole between two boards so that your pegs and safety bars would be resting on the seam seems like a prime setup for disaster. The way you have it now makes the most sense structurally.
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