The Sim Racing Rig

This extrusion rig is built from a Bosch Rexroth (BR) compatible extrusion produced by KJN in Leicester, UK. The extrusion comes with a 10mm slot. I was replacing a wooden rig that didn’t allow for much adjustability – extrusion excels in this aspect and is a near perfect material for building your own sim-rig

Version 1 was designed around Logitech G923 pedals and after a later upgrade to Heusinkveld Sprint Pedals when I decided to flip my pedals in order to improve access to the mounting bolts I added the longer front uprights with some horizontal supports (Version 2). The final step was to add a support on the side for gearbox/handbrake mounts (Version 3). At the same time I changed the way the dash mounts were done for a cleaner design.

Version 3

BOM

The following build of materials (BOM) is for Version 3 and covers what one would need to order from KJN (or alternative) to replicate the rig. Download a PDF Drawing here.

Extrusion Cutting List

	Description	Type	Length	Qty
SM	Side Member	120 x 40	1350	2
FPP	Front Pedal Pillars	80 x 40	500	2
BP	Bulkhead Pillars	80 x 40	1200	2
CM	Cross Members (between SMs & FPPs)	80 x 40	500	5
DCM	Dash Cross Member (between BP)	80 x 40	580	2
DR	Dash Rails	40 x 40	600	2
SR	Seat Rails	40 x 40	540	2
SDR	Side Dash Rail	80 x 40	800	1
SDRS	Side Dash Rail Support	40 x 40	360	1

Connection Elements

Description	Type	Qty
Right Angle Bracket	40 x 40	49
Tilting Bracket (with fixings)	40 x 40	4
T-Bolt & Nut (2 / Bracket)	M8 x 20	106
T Nut (Pedal Board, Dash and Seat Rails plus some extras)	M8	20
End Cap	120 x 40	4
End Cap	80 x 40	5
End Cap	40 x 40	6

Driver Positioning and FOV

The following image as a guide for correct seating position and control arrangement. Everything seems to be in the right place or close enough and there is plenty of adjustment. With the Modern FOV Calculator I was able to get an acceptable FOV with a 50″ screen.

The Seat

I have fitted a front seat from a Honda Civic Type R to the rig. The original mount brackets were ground off and the rivet holes left increased to 8.5mm. This allowed M8x12mm bolts with T-Nuts to be used to secure the seat to the seat rails. Note: This is an early picture and I later adjusted the seat so it sat ~5mm from the end of the rails not the ~100mm as shown as this gave better leg length range.

Dashboard

The dash is made from a piece of Oak although other most other woods would work. Its 20mm x 770mm x 240mm and this zip file contains a PDF of the drawing and a DXF.

Pedal Flip Upgrade

In order to flip the Heusinkveld Sprint Pedals a small shim was required to attach the back bolts. You can download it from Printables.