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This is just how I did it, I'm not saying its perfect. Has worked just fine through P90X and Insanity and I now use it for a mashup of the P90X, Insanity workouts and Yoga. Base Layer is DriCore 2' x 2' tiles ($5.97 each from Home Depot) Middle are Gym equipment rubber 1' x 1' tiles ($42 -25% off coupon for 12 pack from Sports Authority) Top layer are Anti-Fatigue foam 2' x 2' floor tiles ($19 for 8 from BJ's) I made my surface 8 feet by 6 feet and that came to about $213. There are tons of different brands to pick from for the gym and foam flooring from several retailers, I've only seen Home Depot sell the Dricore and nothing else like it locally. The Dricore is to prevent mildew buildup under the exercise surface, the rubber and then foam is for a gradual increase in firmness. I found the lightweight foam bottomed out right away from impacts and slid around. With the rubber there's the added weight and grip to stop the surface shifting and an extra level of firmer cushioning for heavier impacts. If you don't have damp issues you can just put the rubber/foam down and skip the dricore. Likewise if your younger and don't need the extra padding then you could skip the foam.
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