Custom Racing Simulator Rig

Inspired by my time on the UWFM team and conversations with experienced drivers, I developed an interest in sim racing as both a driver-training tool and an engineering challenge. My goal was to create an affordable, modular racing simulator rig that could evolve over time; starting simple, then iterating toward a highly adjustable and immersive platform while documenting my design findings and driver development along the way. 

The project began by evaluating commercially available rigs and analyzing custom builds, then modeling early concepts in CAD. Key design objectives included:

• Ergonomics – Adjustable seating and pedal positions to replicate real-world driving postures (from open-wheel to GT) and accommodate different driver sizes.

• Serviceability & Upgradability – Modular construction for future modifications and hardware upgrades.

• Structural Stiffness – A rigid frame to withstand steering moments, braking forces, and driver weight.

Several material options were evaluated: wood, steel or aluminium tubing, aluminium extrusion, and even a carbon-fiber tub. Aluminum extrusions were ultimately selected for its strength and flexibility for modular upgrades and adjustability, despite the higher cost compared to steel material options.

This project has already delivered measurable performance gains. Switching from a single monitor with a low refresh rate to a low-end VR headset, for example, improved spatial awareness and vision tracking, cutting lap times by over 10 seconds on some circuits. The modular design provides a platform for continued iteration, with future plans including:

• Haptic feedback systems to replicate vibrations from engines, ABS, and shifting.

• Environmental simulation such as variable-speed fans for wind or shakers for road-surface effects (gravel and curbs).

• Advanced motion integration for feeling cornering and suspension dynamics, and road texture.

Balancing cost, adjustability, and performance, the simulator rig continues to evolve as both a personal training tool and an engineering exercise, bridging my passion for motorsport with real-world design and problem-solving.