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.
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
|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|
|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.
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.
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.