Elliptical Fix

I was working out on my elliptical one morning and the console started wiggling around as I worked. The month prior to this the center post with the console attached was very firm. I finished my workout thinking I had some bolts to tighten. It seemed reasonable to me, after all I had been working out about an hour a day, every day for over a month. Plus my wife and daughter had been using it fairly frequently.

I was surprised to find that there was nothing to tighten. What happens is that there is a square post under the plastic cover and into that goes a smaller square post with 4 bolts to hold the smaller post into the larger, coming up from the floor. So one fits inside the other in a sleeve arrangement.

At the top of the smaller square post is a 1/8′ thick circle disc. That disk is welded to the top of the square post and also welded into the round post upon which the console is attached and the arms pivot points are attached. So the weld had broken and the upper, round post was rocking around as I worked out.

I was surprised that they didn’t insert the square post farther into the round post and just had the disk inserted in the very end with 4 poor welds holding it all together. So I took a dremmel tool and a couple of sanding disks and ground the corners of the small square post, about 3 inches down from where the circle disk is welded to the top of the small square post.

Elliptical Fix

Elliptical Fix

Then I lifted the smallsquare post up about 2-3 inches from where the 4 bolts held it in the larger square post. It ends up that only 2 holes line up so now there are only 2 bolts holding the square posts together, but it is quite strong. With the additional 2-3 inches of height and the corners ground off, I was able to take the top round post and drive it down over the small square post so there is approx 3 inches of post inside the round tube. I took the console off of the round post and used a hammer to drive the round post down over the disk and small square post abd then reattached the console.

It is now very stable and it is not going to go anywhere. The elliptical still works great and I have fierce workouts on it. The procedure took me a couple hours but most of that time was spend taking the elliptcal apart to figure out what was wrong. If I had known my plan of attack, it might have taken me 30 minutes.