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Hoddem's Aluminum Rig V2 (3-DOF, SFX, VR)

Discussion in 'DIY Motion Simulator Projects' started by Hoddem, Feb 17, 2020.

  1. Hoddem

    Hoddem Well-Known Member

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    I needed to cut the 4x3x1/4" aluminum angle and while I know that my chop saw could do it as is, I felt that this was as good of opportunity as ever to buy a blade designed for cutting aluminum.

    On the left is the blade that came with my saw, I use it for just about everything except finish work. It has probably cut several hundred cuts in aluminum extrusion. The new blade is on the right, it set me back a fair amount.

    upload_2020-11-15_12-36-51.jpeg

    all I can say is WOW! I wish I had invested in this blade years ago, it cuts through aluminum plate like butter and it is so much quieter too. my only real complaint is that it turns the chips into dust so cleanup is a bit more of a concern.

    upload_2020-11-15_12-38-15.jpeg


    I cut my angle to length and nicked the corners off. I also cut up some 1/4" plate to act as feet.

    upload_2020-11-15_12-40-31.jpeg

    Next I laid out all the hole locations and then drilled a lot of holes, exactly 99 of them.
    I had to rig up a special jig to hold the angle in a way that I could drill from the flat side.

    upload_2020-11-15_12-42-34.jpeg

    I did a quick sanity check before finishing the remaining parts.

    upload_2020-11-15_12-43-27.jpeg

    After drilling everything, I spent another hour or so cleaning everything up with a sander.

    upload_2020-11-15_12-44-0.jpeg

    Back to the bathtub for a wash.

    upload_2020-11-15_12-44-20.jpeg

    Finished parts all clean and ready for assembly.

    upload_2020-11-15_12-44-52.jpeg

    upload_2020-11-15_12-44-58.jpeg
    • Like Like x 3
  2. Hoddem

    Hoddem Well-Known Member

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    I started assembly by first disassembling my simulator. I had to disconnect all of the electronics and then pull the actuators back off. I was joking to my buddy that it looks like my ride got jacked with it up on blocks.

    upload_2020-11-15_12-46-49.jpeg

    I started to assemble the first actuator and quickly realized that I wasn't happy with how it was going.

    upload_2020-11-15_12-47-36.jpeg

    I am trying to be extra careful here to align everything because I know that any skew will result in amplified problems later. The actuator needs to be as vertical as possible or else as it goes up and down the distance between actuators will change this will be in addition to the already discussed change in distance relative to the platform. Ultimately I was not happy with how the first one went together and I came up with a setup fixture.

    upload_2020-11-15_12-51-22.jpeg

    still not completely satisfied I added a square reference.

    upload_2020-11-15_12-51-53.jpeg


    upload_2020-11-15_12-52-2.jpeg

    I was satisfied with the new assembly method and I was finally able to mount the first actuator to the control box.

    upload_2020-11-15_12-52-52.jpeg

    upload_2020-11-15_12-52-57.jpeg

    upload_2020-11-15_12-53-3.jpeg


    rinse and repeat for the remaining two actuators.

    upload_2020-11-15_12-53-25.jpeg

    With the help of my wife I was able to get the base set in its semi final resting place. I will be moving up against the wall, but will leave it here until all of the wiring is completed. by design It just barely fits on my 4x6 mat.

    upload_2020-11-15_12-55-1.jpeg

    Now I had to switch gears and focus on the rig. I needed to add the extrusion that the actuators will push on.
    I am a little short on pictures for this part.

    I had to remove the front and rear cross members from the frame, not to big of a deal, but not exactly easy either.
    upload_2020-11-15_12-56-23.jpeg

    They needed to be drilled for the hidden fasteners that will hold the new extrusion assemblies.

    upload_2020-11-15_12-57-0.jpeg

    Assembly of the front, again all hidden fasteners.

    upload_2020-11-15_12-57-9.jpeg

    rear assembly is identical except the top member extends 9" on either side.

    upload_2020-11-15_12-58-32.jpeg

    upload_2020-11-15_12-58-40.jpeg

    upload_2020-11-15_12-58-48.jpeg

    It looks pretty funky on the ground, I was able to convince a neighbor to help me throw it up on the box. It is pretty heavy, but manageable for 2 guys.

    upload_2020-11-15_12-59-49.jpeg

    upload_2020-11-15_12-59-53.jpeg

    upload_2020-11-15_12-59-58.jpeg

    The rig is just sitting on the actuators right now, I have some cups printing now that I will throw on to keep it from accidentally sliding off. Overall I am pretty happy with the results. I may need to add some reinforcing plates/brackets depending on how much flex I get.
    • Like Like x 4
    • Creative Creative x 1
    Last edited: Nov 15, 2020
  3. Hoddem

    Hoddem Well-Known Member

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    I need to fit all of this into my new enclosure.

    upload_2020-11-15_13-3-41.jpeg

    I decided to ditch the computer case and go open air with my simulator PC. I picked up a frame kit off amazon and after a month of transit time it showed up at just the right time.

    It doesn't look like much, but it is actually pretty well thought out.

    upload_2020-11-15_13-5-32.jpeg

    Here is the old case stuffed with all sorts of out dated tech. FYI I am planning on upgrading to essentially a new computer once the AMD, INTEL and NVIDIA new release craziness is over. also I will be getting a reverb G2 or index at the same time, depending on how the reviews turn out for sim racing specifically.

    upload_2020-11-15_13-7-1.jpeg



    After gutting the old pc

    upload_2020-11-15_13-8-59.jpeg

    ready for the scrap yard

    upload_2020-11-15_13-9-41.jpeg

    Here is the final configuration for my new open air PC, I removed all but the essentials. I still need to make some 3d printed parts to stack the two hard drives, but all in all it ended up pretty good.

    upload_2020-11-15_13-11-47.jpeg


    upload_2020-11-15_13-12-0.jpeg

    upload_2020-11-15_13-12-12.jpeg


    My next big task is to move all of my electronics into the new box and begin wiring everything again. That will include a new relay bank and new control panel with switches to turn everything on as well as the red/yellow/green buttons for the motor controller.
    • Like Like x 3
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  4. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

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    My Motion Simulator:
    3DOF, DC motor, JRK
    Incredibly detailed work @Hoddem, I am looking forward to the next update an live testing :thumbs
  5. cfischer

    cfischer Active Member Gold Contributor

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    A pleasure seeing all the attention to detail and craftsmanship. Looking forward to reports back on the actuator setup as this is something I want to do with my rig too.
    • Agree Agree x 1
  6. Hoddem

    Hoddem Well-Known Member

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    @cfischer, @noorbeast

    Thanks Guys, I honestly do enjoy the building process as much or more then the actual racing. This has been a pretty time consuming phase of the project though and I am very much looking forward to being able to do some racing.
    • Like Like x 3
  7. RacingMat

    RacingMat Well-Known Member Gold Contributor

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    My Motion Simulator:
    2DOF, DC motor, Arduino
    :o: my favorite part: ignition ramp!

    upload_2020-11-19_14-19-27.png

    your place is so clean and tidy! respect!
  8. Hoddem

    Hoddem Well-Known Member

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    Thanks, the idea was that you could get in the simulator and start everything right from the seat. Plus the cool factor when you are booting everything up is level 10.

    Also I do my best with the garage, the biggest challenge is keeping stuff from accumulating.
    • Winner Winner x 1