Average Joe Innovations — Better Than OEM™

A disc inside my dumbbell cracked or broke

This is implied by the 2025 recall. For 552s and 1090s sold before mid-2025, the internal discs that enable weight selection were made partially or entirely of plastic depending on the model, and that plastic eventually fails under repeated load. Once it breaks, the weight plate it was holding can come loose or fall off entirely. To address the issue, you can replace the factory discs with solid metal ones. See the selection of Average Joe Disc Fix Kits above.

A weight plate fell off or feels loose while I'm lifting

This usually means a disc has already failed, or the locking pin isn't holding the plate selection the way it should, or the tab on the weight plate is damaged. Stop using that dumbbell until you've fixed it. Replacing the discs and pins with solid metal Average Joe upgrades addresses the first two problems. And free DIY videos on the Average Joe YouTube channel address the weight plate tab problem — using inexpensive, readily available materials, with no purchase from Average Joe Innovations required. It's a failure mode the manufacturer has never called out in any recall, and one that, as far as I can tell, still exists even in the brand-new, post-recall Results Series.

My locking pin won't catch, slips, or doesn't hold the weight selection

Factory locking pins wear out and snap the same way discs do. A worn pin can let the selector dial slip out of position mid-set, which is another way that plates end up falling. A new solid metal Average Joe locking pin kit addresses this. If you have an older 552 Series 2 or a knockoff, you may need some of the specialized longer pins for that application. See the Average Joe Locking Pin Kit options above.

My dial broke or I just find it uncomfortable

Factory dials can eventually fail. This was the hazard cited in the 2012 recall, which involved the risk of weight selector dials potentially failing. This allegedly affected only about 17,000 units of the 1090. The dial design itself was never changed following that recall. Even on dials that haven't failed, they can be uncomfortable when resting them on your thighs in between sets on a bench. A replacement dial kit is a straightforward upgrade and a noticeable improvement in feel and appearance. See Average Joe Dial Kits above.

My grip is uncomfortable, slippery, or its rubber sleeve has come loose

The factory grips are broadly disliked. Some people find the 1090 grip contour and texture awkward and uncomfortable. Many 552 owners dislike the grip contour and feel, find it too slippery, or have had the rubber sleeve come loose from the underlying metal. Average Joe knurled stainless steel grips provide the look, feel, and long-lasting durability of commercial-grade equipment. Available in 30mm, 35mm, and 40mm depending on what feels right in your hand. See the Knurled Grip Kit options above.

My end caps are missing, no longer stay put, or just look worn out

If you've disassembled your dumbbells before, you already know these end caps eventually look terrible or stop staying in place. The end caps are mostly cosmetic, but they're also the easiest, cheapest way to freshen up these dumbbells. See End Cap Kits above.

Should I repair my Bowflex SelectTech 552/1090, or just buy the new Results Series?

Repairing makes sense for almost everyone. A full set of metal discs costs a fraction of a new Results Series set, and it addresses the same problem the manufacturer addressed on the new model: swapping plastic discs for all-metal. You already own the dumbbells, the bases, and everything else that hasn't failed. There's no reason to replace the whole set just because a handful of internal parts wore out. The exception is if your dumbbells have a structural problem that replacement parts cannot fix; in that case, no aftermarket parts seller, including me, can address that for you.

Will these upgrades work on knockoff or off-brand SelectTech-style dumbbells?

Usually, yes. If your dumbbells are a direct visual clone of the 552 or 1090, the same parts generally fit, with the same manufacturing-tolerance caveats that apply to genuine units. See the compatibility questions below for specifics.

2012 RECALLWas the 2025 recall the first time this problem was officially acknowledged?

No. According to CPSC records, the manufacturer issued a recall in 2012 as well, more than a decade earlier, citing weight plates detaching during use. That recall was limited to approximately 17,000 units of the 1090 model, covering a specific range of serial numbers. The official cause was attributed to the weight selector dial, not the plastic discs themselves.

The underlying disc design was never changed across any model or generation after that recall. The same plastic components continued shipping in every 552 and 1090 sold between 2012 and the eventual transition to the Results Series.

In March 2024, Bowflex Inc. filed for bankruptcy. Johnson Health Tech Trading acquired the brand, and in 2025 issued a new recall, this time covering nearly 4 million units spanning over 20 years of production across both the 552 and 1090 lines.

Both recalls are a matter of public record and can be verified on the CPSC website.

2025 RECALLWhat does the 2025 recall mean for my dumbbells?

In June 2025, the manufacturer issued a safety recall covering nearly 4 million pairs of SelectTech 552s and 1090s sold over the last 20+ years. The reason, officially described as weight plates dislodging from the handle during use, is exactly what Average Joe Innovations has been solving since 2019: the internal plastic discs break, causing plates to detach and fall.

The "Fix" vs. The Reality: Rather than sending out replacement parts, the manufacturer offered a credit voucher toward new products, often prorated to a fraction of the cost of a new set for dumbbells bought before 2024.

Can I still use them? Yes. Owners have the right to repair their own property. Legal restrictions generally apply to selling or donating a recalled product, not to fixing it, since selling a known hazard carries personal liability risk.

The Ultimate Validation: When the manufacturer released the Results Series replacement line, they swapped the internal plastic discs for metal ones — effectively adopting the standard Average Joe discs have used since 2019.

Disclaimer: Average Joe Innovations, LLC is a small business, not a law firm. Information regarding recalls, resale restrictions, and right-to-repair is general information only and not legal advice. Consult a licensed attorney for specific questions about your rights.

Will your parts make my dumbbells safe?

Disc fix kits directly address the failure cited in the recall: weight plates dislodging from the handle during use. Replacing plastic discs with solid aluminum removes that weak point, the same conclusion the manufacturer effectively reached with its Results Series. Average Joe Innovations cannot declare an entire recalled product "safe" as a complete system, since that determination is not one any aftermarket parts seller can make, but the kits address the problem the recall was issued for.

Are 3D-printed plastic discs a safe alternative?

In a word: no. Given what caused that recall, swapping one plastic part for another doesn't solve anything — a 3D-printed disc is still plastic. The manufacturer couldn't make plastic work with a multi-million dollar budget, so there's little reason to expect better results from an eBay or Etsy seller with a 3D printer, on a part that needs to hold 50–90 lbs in each hand over your head.

Since 2019, dozens of discs and locking pins have been bench-tested; every OEM and 3D-printed part failed at forces significantly lower than the metal alternatives. When you're holding 50–90 lbs in each hand over your face, plastic isn't up to the task.

What about carbon fiber discs — isn't carbon fiber stronger than plastic?

Not in the way it's used in these 3D-printed replacements. The "carbon fiber" on Etsy and eBay replacement disc listings isn't the woven fabric used in bike frames or exotic supercars — it's a plastic 3D-printing filament with short, chopped carbon fiber strands mixed in. It stiffens the plastic, but it doesn't fix the underlying issues of the factory discs.

Two problems compound here. First, chopped fiber mainly improves stiffness, not fatigue resistance, meaning it does little for a part's ability to withstand thousands of normal load cycles without a crack starting and growing. Second, these parts are typically 3D printed using FDM (Fused Deposition Modeling), which adds its own weak point: printed plastic is built up in layers, and the bond between those layers is never as strong as the plastic itself. Chopped carbon fiber sits inside each layer, not between them, so it does nothing to reinforce where every printed part is already weakest, the seams where layers meet.

Those weak seams run through the whole disc, and it's the raised lip around the outer edge and the hub around the center hole — the highest-stress areas under normal use — where it matters most. In other words, an FDM-printed carbon-fiber disc doesn't strengthen the areas that were already the weak point in the original design; it simply introduces its own version of the same problem.

In short, carbon-fiber-infused plastic is still a type of plastic, printed in a way that doesn't solve the underlying problem.

Can I drop my upgraded dumbbells or use them for bodyweight exercises?

No. SelectTech and Results Series dumbbells, whether stock or upgraded, are not designed to be dropped or used to support bodyweight. Drops and bodyweight exercises generate forces far higher than normal use such as presses, rows, curls, or flys. Disc Fix Kits and Locking Pin Kits improve durability during ordinary training but are not indestructible, and damage from dropping or bodyweight use is not covered under warranty. Even if upgraded components survive an impact, other parts such as dials, crossbars, shafts, bases, or weight plate tabs may not.

Will a used OEM or knockoff part fit my dumbbells?

Short answer: maybe, but it's a gamble. These dumbbells were mass-produced for years with loose manufacturing tolerances, so no two sets are exactly alike; even genuine OEM parts vary from pair to pair. Most online sellers are parting out old, discontinued units without realizing the part may have come from a slightly different version. Average Joe upgrade kits are designed to account for the widest possible manufacturing variance; about 95% of installs are plug-and-play, with guides and support for the 5% of outliers that need fine-tuning.

Will AJI upgrades fit my SelectTech 552 or 1090 dumbbells?

Short answer: yes, in most cases the upgrades fit right out of the box. Grips, dials, and end caps fit the vast majority of OEM and knockoff 552 and 1090 dumbbells with no modifications. Discs and locking pins fit about 95% of dumbbells out of the box; for the other 5%, fit can usually be fine-tuned (shimming or light sanding/filing for discs, minor modification for pins), or the upgrade can be returned under the 30-day guarantee for a refund minus original shipping, payment processing fees, and sales tax.

Do AJI upgrades fit the manufacturer's new Results Series?

Yes. Customers are already successfully installing grips, locking pins, dials, and end caps on brand-new Results Series sets out of the box, since most parts remain virtually identical to the older models. Whether the Results Series fully resolves every cause of plate detachment remains to be seen; other AJI upgrades address contributing factors the manufacturer has never publicly acknowledged.

Will AJI discs fit my knockoffs?

Yes, most knockoff dumbbells are compatible. Generally, if your dumbbells are a direct visual clone of the SelectTech 552 or 1090 design, AJI discs and locking pins will fit, with the same fine-tuning caveats that apply to genuine OEM units due to similarly loose manufacturing tolerances.

Which should I choose: Aluminum or Stainless Steel?

The short answer is: you can't go wrong. Both materials were chosen because they're what the founder wanted for his own dumbbells — aluminum first, as an affordable upgrade over factory plastic, and stainless steel added years later as the material he always wanted but couldn't initially afford.

Aluminum disc kits are the "workhorse" solution: durable, high-strength, and built to replace plastic internals with metal that won't give up, ideal if you want reliable dumbbells without spending a fortune.

Stainless steel disc kits are the "money-is-no-object" solution, adding weight, a raw-steel look, and a built-like-a-tank feel comparable to high-end commercial gym equipment.

Both materials are naturally corrosion-resistant and will likely outlast the dumbbells themselves — it's a choice of feel, not of better versus best.

Are single replacement discs available?

Yes. Cast aluminum discs can be purchased and installed individually.

What are "Factory Seconds" and what are the terms?

Factory seconds are kits that are functionally identical to standard kits but have cosmetic imperfections, such as nicks, scratches, spots, or irregular casting/knurling, that fall outside standard quality control. Minor surface variations only noticeable under close inspection do not qualify. In exchange for these blemishes, factory seconds carry a 20% discount; the parts remain structurally sound with the same performance as standard kits.

Eligible for Factory Seconds: Locking Pin Kits (cast aluminum, all models), Dial Kits (all models), End Cap Kits (black Teflon-coated aluminum, all models).

Never available as seconds: Stainless steel 3rd Gen Disc Fix Kits and U.S.-machined 6061 Locking Pin Kits — any part not meeting quality standards is recycled rather than sold as a second.

Terms: All factory seconds sales are final. Returns are accepted within 30 days only for verified fitment/compatibility issues. Shipping, taxes, and payment processing fees are non-refundable.

How difficult is the installation process?

It's mostly a matter of following the steps. Someone comfortable working with their hands can usually finish a disc upgrade in 10 to 30 minutes; newcomers following the installation videos should plan for about 30 to 60 minutes on the first dumbbell, with the second going much faster once the parts and process are familiar.

Do you offer discounts?

Not in the traditional sense — kit pricing starts at $10–$12.50 per disc depending on model, already competitive with plastic alternatives. Two exceptions exist: Factory Seconds, offered at a 20% discount when available (availability is unpredictable), and Volume Orders, which receive an automatic 10% discount when the order total before shipping exceeds $500.

How do I place an order?

New customers: use the order form on the site; an invoice is sent by PayPal by default, with Venmo, Zelle, or Revolut available on request. Existing customers: can skip the form and email directly for a fast-tracked invoice, as long as their information is already on file and unchanged.

How do I know an email is really from you, and not a scam?

Email spoofing is real, and scammers can fake a "from" address. Average Joe Innovations will never ask for a credit card number, bank or routing numbers, Social Security number, account passwords, gift card codes as payment, or wire/crypto transfers. Every order is invoiced and paid through PayPal, Venmo, Zelle, or (for some international customers) Revolut, always to an account clearly tied to the business.

Red flags include: urgency or pressure tactics, requests for payment info already provided, login "portals," unexpected attachments, unfamiliar tone or phrasing, mismatched reply-to addresses, and lookalike domains other than averagejoeinnovations.com or knurledgrips.com. Anything suspicious should be verified through the site's contact form rather than by replying to the email.

Is there a Guarantee or Warranty?

Yes. All kits currently in production are backed by a 30-Day Guarantee and a 10-Year Limited Warranty. First and second generation Disc Fix Kits are no longer under formal warranty but continue to receive unofficial support as long as spare parts remain available, which is expected for the foreseeable future. The guarantee and warranty terms may be updated at any time, with changes applying only to purchases made after the update.

Do you ship internationally?

Yes, worldwide via USPS, UPS, or FedEx where service is available, with every shipment trackable. Kits have shipped to customers on six continents. Shipping rate is calculated for the specific destination address and included in the invoice.

What are the typical shipping costs?

U.S. orders: generally range from about $10–$25 or more depending on order size and weight. International orders: typically via FedEx, usually ranging from about $20–$50 or more. Customers can request a precise estimate before ordering, and can specify a preferred or avoided courier.

Why are shipping costs going up in April 2026?

For the first time in six years, shipping rates were adjusted. USPS, UPS, and FedEx raised their rates between 5.9% and 8.0% in a single year, and packaging material costs followed suit. Domestic U.S. orders see an increase of $2.00 to $5.00 depending on location; international rates already reflect current carrier pricing on the invoice.

Will I have to pay sales tax or import duties?

U.S. customers: state and local sales/use tax is added to the invoice where applicable by law. International customers: the AJI invoice does not include VAT, import duties, or brokerage/handling fees; these are billed directly by the courier or destination customs agency upon arrival.

What happens if my package is lost or stolen?

If tracking shows "Delivered," the courier has fulfilled its contract; Average Joe Innovations does not provide free replacements for stolen packages or shipments lost by the courier, and a claim must be filed with the courier directly. Risk of loss and title pass to the customer upon delivery to the carrier. Most standard shipments include up to $100 of default insurance coverage, with additional coverage available on request. A Signature Requirement (about $4 or more) is recommended for anyone concerned about porch theft.

Can you lower the value on the customs form?

No. Falsifying export information is a federal offense under 13 U.S. Code § 305, carrying heavy fines and potential jail time. This request is respectfully declined.

How long has AJI been in business?

Since July 2020, following a personal mission that began in 2019. After years of dealing with failing plastic dumbbell parts and trying used parts and DIY fixes that didn't hold up, the founder designed metal discs to replace the failing plastic ones and shared the process on YouTube in 2019. The personal project grew into a full-time business serving thousands of customers worldwide, still working with the same U.S. and overseas manufacturers used from the beginning.

What is your typical response time?

The founder personally handles every aspect of the business, from design to shipping to customer support, and typically responds within 24–48 hours.

Is AJI affiliated with OEM manufacturers?

No. Average Joe Innovations is not affiliated with any OEM manufacturers. Bowflex® and SelectTech® are registered trademarks, and Results Series™ is a trademark, of Johnson Health Tech Retail, Inc., none of which have been involved in the development, marketing, or sale of AJI products, and none of which endorse them.