Misanthrop's spontaneous racing sim project (3DOF+Surge+2xTL)

Greetings from Germany.


I decided to build a fullmotion setup about two weeks ago. So far exclusively for racing like ACC, GT7 or iRacing in the future.
Almost 10 years ago I welded a simrig out of steel tubes for two friends. I only fulfilled my wish at the end of 2018. As I worked a lot with Bosch profiles in my job and I attach great importance to flexibility, the decision was quickly made.


At that time with Thrustmaster T300 and after few weeks with many mods, later with Loadcell pedals and Shifter.


Switched few years later to Fanatec and have designed extra holders for the base

and this is the current situation.



So this for the past. Two weeks ago i decided to build a fullmotion setup.
I did a lot of reading, looked at many different existing products as well as DIY projects and only very few of them were attractive, most of the products simply too expensive for me.
After all the research, I liked designs that didn't sit too high and didn't take up too much space. I also think that most rigs are completely overengineered. Since I already have a rig made from Bosch profiles and I still absolutely love it, I wanted to continue using it and create everything based on it.


That's how I came across the SFX100 components, which are also very good value for money. When searching for all the components, however, I realized that there is no 100x100 ITEM profile in Germany. So I looked for the 90x90, checked it out, found out that nothing would fit and then redesigned everything last Saturday.



The actuator is based on a 90x90 ITEM profile with an 80ST motor, other components are almost the same, but the design is different to the SFX100 system. The actuator has 175mm stroke.

I also want to integrate a surge system right away, which I designed yesterday.

I have intentionally left out all brackets and fastening elements in the design that I do not design myself.
Current dimensions 1.8m x 0.9m
At the moment I am trying out double traction loss, but I don't have a finished design yet and am currently testing which one I like visually, isn't too high and at the same time is simple and easy to implement. I will submit pictures in the next few days.

Most of the parts have been ordered in the meantime and are arriving daily. The parts that have already been designed are already being 3D printed. Depending on the intended use, initially in PLA or PETG.

What motors and drivers are you going to use?

Nothing fancy, the often used 80ST-M02430+AASD 15A

Spent a lot of time over the last few days building tractionloss front and rear, unfortunately never with a result I was really happy with.

The vertical actuators will have SP22 ball rollers. They will be placed on 3mm steel plates (currently not on pictures of the construction)

The front shaft of the tractionloss will have a hinge on the outside to hold the frame in position. Two flange bearings at the rear.


The stroke of the Tractionloss is 180 mm in both directions. Not yet completely finished, but the basic concept is ready. I am always open to ideas and suggestions.

Could you show what Arduino code you use and connections, thanks.

Have bought a Thanoscontroller in addition to a MagicBox, everything else in the future wheneverything arrived.

thank you

More and more parts arrived and almost all print parts are done.



Since I want to have the complete load on the aluminum profile and not on the 3D-printed parts, I drilled out the linear bearings with an 11mm hole to be able to screw them directly to the profile or to transfer all forces directly to the profile. This also gives a much cleaner look. This also gives a much cleaner look.



As the existing bucket seat was already very old, I decided to go for something new



Surge and Tractionloss are now also fully constructed. The last parts for this are currently being printed


I'm currently waiting for the FK12 fixed bearings and the DOF MagicBox before I can start the final assembly. But that's not so bad as I'm currently very busy at work and I'm also moving my workshop.

The last parts arrived and had spent some time the last days to put the puzzle together.

Bought an server rig



And finally yesterday i got the software running with ps5 and gt7





At first now only with 4 servos for testing and it works very good.

Spent also half an hour to draw an Housing for an estop, printed it yesterday and i am happy with the result




Next steps:
-Wire the server rig properly, 4 main servos, surge and TL should be able to be switched on and off separately

-Install components for surge

-Proper non-slip base

-Fine tuning


-Draw and order the final parts for TL front and rear

After I had some problems with SRS and was about to switch to SimTools, everything is now working as I imagined. Maybe I will try SimTools in the future as SRS seems to be not well thought out. The squeaking noises unfortunately come from the Fanatec V3 pedals.

So that I have motivation to upgrade my current PC for SimRacing, I have bought three curved screens, the stand will be measured in the next few days and then profiles will be ordered again.

I've already installed TractionLoss, I still have to measure the base frame and order the profiles, but everything should be ready in no time.

Great build. Do you have any further information on what pieces you used for the sliding mechanism?

You mean surge? SFU1605 with HGR20 linear rails with 190mm stroke and 80st motor. Everything else i designed and printed myself

Yes, exactly. Did you design what slides on the linear rails or did you source a trolley of some sort? I'm interested in making a similar surge setup.

Sliders are HGH20 with printed Adapter that i can mount them on the Bosch profile.

You see them on my desk on many pictures.

At least a little update. The rig has been on its way to Japan for 6 weeks now and has unfortunately not yet arrived. Unfortunately, nothing more has happened during this time. The months before that I was busy with small optimizations and fine tuning.

After many software problems with SimRacingStudio, I switched to Simhub, which turned out to be the best decision.

Unfortunately, the software tuning then started all over again, but the rig finally did what it was supposed to do.

Since I moved the rig to another room shortly before I moved, I was able to test my triple monitor setup. I also added Iflag, for which I am now printing enclosures and a stream deck and a new 5" dashboard




I also disassembled the actuators and checked for wear on all 3D printed parts. To my astonishment, everything is intact and in perfect condition. So I regreased and reassembled them.

Only surge is currently installed. I initially rejected the idea of assembling tractionless, partly because I wasn't completely satisfied with the design. Now that I have my head free again after my move and have come up with a few new ideas, I will work on these constructively in the near future. The complete substructure and connection to the actuators will be changed.

Short Update about Tractionloss. I´m happy now with the outcome. The picture only shows the basic idea. Now all the 3D printed parts have to be designed.
Height from actuator bottom to floor is only 8cm, which is much lower than I thought possible. Maybe tomorrow I will design the connection between the HGH20 rails to the two 30mm precision shafts, this connection will include a roller ball bearing to compensate for the angle and will also include a support bearing for the leadscrew.

Picture not working

Have uploaded them directly here, so should work and i can see them.





So, the parts for TL are all designed and ready to get ordered or printed. Ordered already the 30mm precision shafts(not easy to get in Japan), they should be delivered end of October. My 3D-printer is still on the way to Japan. So i think everything will be ready in November.

I am really happy with the outcome. Some Measurements:
Tractionloss:
- 350mm stroke(175mm in each direction)
- Only 80mm additional Height

Overall:
- Vertical Actuator 170mm stroke
- Surge 190mm stroke
- Overall only 400mm Height to the Seat connection when Actuators are in waiting position(it´s possible to get it even lower, maybe in future)
- everything with super lightweight Profiles from Bosch
- most 3D-printed Parts are made of PETG, some out of ASA
- everything designed by myself





Now i will design and prepare other things like my two Iflag LED-Panels, Buttonbox which will include my Stream-Deck and MotionRig-Buttons, also Holders and everything for my Triple Screens. So i think the next Update will be when i get everything together.

After 4Months my Simrig arrived.

All parts for Tractionloss are printed and ready for assembly. Unfortunately i haven't really much time for it at the moment.




Also i wanted a better Wheelbase, Unfortunately, Fanatec availability has been poor for months. Either the DD+ Wheelbase is not available and/or the QR2 adapters are not in stock. After I had a look around, I noticed the Simagic system extremely positively, both visually and in terms of price/performance. So I opted for the Simagic Alpha Ultimate, which is cheaper with the GT Neo steering wheel than a Fanatec DD+. And with the Fanatec Base, I would also have had to upgrade to QR2, which is simply outrageously expensive.




The last days i designed some parts to mount the Simagic stuff and new brackets for the TripleScreen, I now have to print these parts, unfortunately I have a lot of warping with the Bambu filament which has already caused a few misprints and is costing me time. The Vesamounts for the Triplescreen will be fully adjustable like the ones from Simlab or TrakRacer, they are already printed, but forgot to make pictures.

So it finally moves again.

https://youtube.com/shorts/GY3mxwrb84E?si=ZyRqhKLSQuCkRl9g

Had some issues with windows and had to setup my pc from ground new. My designed Tractionloss system is working great without any issues.

The next weeks i will not have time for my rig. I have now also decided to discard the plans for my triple screen holders and will mount them directly to the rig. Unfortunately this means that I have to redesign everything. But anything else would probably be boring, but the whole thing will only be done next year.