Patent ID: 7922633

Claim:
A method of manufacturing an exercise device, comprising the steps of: providing a bar, the bar comprising an end portion; providing a collar for receiving the end portion, the collar having an inner bore and an outer surface; forming a first surface feature including one of a projection and a recess in the outer surface of the collar; casting a weight section about the collar to form a weight assembly comprising the weight section and the collar, the weight section having a bore with an inner surface; forming a second surface feature including the other of a projection and a recess in the inner surface of the weight section when the weight section is formed about the collar during the casting step; fixing the collar relative to the weight section during the casting step, by engaging one of the first and second surface features into the other of the first and second surface features to interlock the first and second surface features with each other when the weight section is cast about the collar; mounting the weight assembly on the end portion; providing a first securing member; securing the weight assembly to the bar using the first securing member.