The Fitz Roy Climbing Wall is a DIY item that makes Patagonia’s famous peak accessible for kids.

We used a 2500 x 1250 x 15 mm plywood-board and painted it. The hole pattern for the image and the holes for the climbing holds were drilled with an old CNC 3-axis-router. Although the pattern looks complex, there was no scripting involved and everything was prepared with standard software tools.
First we selected a nice image, in our case we decided for an image of Fitz Roy in Patagonia. Then we created a surface with the “heightfield from image”-operation in Rhino, choosing a height of 3mm (see below). The milling is done with “Plunge Roughing”, a standard CAM operation. In Plunge Roughing, the tool makes a series of plunges to remove cylindrical plugs of material. To get our pattern, we chose for an usual large distance of the plunges. The selected tool is a 6 mm-Ballnose-Tool. To use the radius of the ballnose for different hole diameters, the height difference of the surface equals the radius of the tool (this is were the 3mm come from). If the paint is applied before milling, the holes and the white background contrast sharply.
After this operation, the triangular grid of holes for the climbing holds are prepared, as well with the router. Then the plywood is turned and the T-nuts are fixed with a hammer.
As the screws of the holds will pop out at the back of the plywood, it is recommendable to fix it with some distance to the wall in the kids’ room; we used timber profiles of 50 mm depth. In our case, we have a total 97 holes and started with a set of 15 climbing holds. The position of the holds can be altered any time and there are enough T-nuts to get more holds or fix other gear like a rope.
If everything goes fine, the total time needed to build this wall is not more than a day.

Tools: 3-Axis-Router
Materials: Plywood 2500 x 1250 x 15 mm, Paint, 100 Standard 4 Prong T-nuts M10, 15 Climbing Holds
Total Material Cost: ca. 200 USD