Hey guys, long time fan, first time post in here (I think). Ever since finding the DIY thread aaaages ago (around 2005) I wanted to make one. So last year I got a chance by squeezing making one of these for an assignment at uni, and here it is.!
I was thinking of posting this in the cheap DIY thread but the cost kind of blew out a bit, but was still really cheap considering everything in Australia is... well.. more expensive than America. It cost me just under $60 in materials, then lasercutting was through uni. I was in a rush making it (project was already overdue before I even started. Stupid timetabling) so the project took me about 50 hours design and 10 hours manufacturing. I'm not sure how expensive laser cutting is in America, but I think here it would've cost me about $200 ready to go had I gone through cutting properly.
(Copied from Overclockers Australia Forums http://forums.overclockers.com.au/showpost.php?p=11125187&postcount=252)
My design criteria was
- Portability and packability
I wanted something which I could use as I wished. Light weight and flat packable so it can be stored away. Currently its stored in a bag dimensioned 1mx80cmx15cm. I can assemble it in under 3 minutes and you can kind of fold it and takes up around 1.2mx60x80.
- Weight of an 80 kilo driver comfortably in rally without major problems
I've tested with 100kg without a problem.. the spring system in the back of the chair flexes too far but doesn't break. 60cm adjustable feet length. The biggest problem is because it looks like its going to break, people aren't careful. But I've belted it around GT rally tracks on a DFP without a problem.
-Slot based rather than interference fits
No screws or tight fits.. everything interlocks one way or the other. I'm thinking it shouldn't get too much worse as I assemble/disassemble, but cable ties are cheap and stiffens everything up pretty nicely
- Ergo tested using 50 percentile human model in CAD, then validated using crappy makeshift representations.
Hero shot
Click to view full size!
Unpainted
Click to view full size!
All parts laid out
Click to view full size!
My friend in it
Click to view full size!
Click to view full size!
Its still quite heavy but it does the job (transporting it in it's scaffolding is about 10 kilos, and 15 with some special scaffolding which was left over from the laser cutting which keeps everything secure). The biggest problem I have is that the front section is too light at the base so I have to weigh it down with a phone book and using cable ties.
Its made of 9mm MDF, laser cut. I've tried to FEA the seat base plate to optimise it a bit but as far as I know, the webbing is in the right directions (working on tension rather than compression). There aren't any internal sharp corners just in case stress concentrations happen to be an issue. Really the bigger problem is with perception: its making people scared they'll break the crap out of it if they touch it.
I've already started on 'V2', looking to really just stiffen that front section somehow. I'm thinking of designing a new one for manufacturing (low numbers) which I think I'll sell to my friends who were interested for about $200-300, or about $100 on top of manufacturing. The next design should have a stiffer front section, a spot to put a spot for the H-shift (and maybe design a handbrake module). Depends if I can get my hands on the Fanatec wheels for GT5. Also slightly more elegant cable management.
The lessons I learnt for this type of stuff is to make sure you get your ergo right before committing to anything (or put in adjustability). I got the driving height perfect in my mind (which makes it really nice), but the height from the seat to the ground is a bit low so its hard to get in and out. Really didn't think about that. It pays of to validate your ergo before you commit to anything.
Hope this helps someone! And thanks to everyone who contributed to this forum. I pulled heaps of ideas while designing this. Theres some pretty cool stuff happening here.
I was thinking of posting this in the cheap DIY thread but the cost kind of blew out a bit, but was still really cheap considering everything in Australia is... well.. more expensive than America. It cost me just under $60 in materials, then lasercutting was through uni. I was in a rush making it (project was already overdue before I even started. Stupid timetabling) so the project took me about 50 hours design and 10 hours manufacturing. I'm not sure how expensive laser cutting is in America, but I think here it would've cost me about $200 ready to go had I gone through cutting properly.
(Copied from Overclockers Australia Forums http://forums.overclockers.com.au/showpost.php?p=11125187&postcount=252)
My design criteria was
- Portability and packability
I wanted something which I could use as I wished. Light weight and flat packable so it can be stored away. Currently its stored in a bag dimensioned 1mx80cmx15cm. I can assemble it in under 3 minutes and you can kind of fold it and takes up around 1.2mx60x80.
- Weight of an 80 kilo driver comfortably in rally without major problems
I've tested with 100kg without a problem.. the spring system in the back of the chair flexes too far but doesn't break. 60cm adjustable feet length. The biggest problem is because it looks like its going to break, people aren't careful. But I've belted it around GT rally tracks on a DFP without a problem.
-Slot based rather than interference fits
No screws or tight fits.. everything interlocks one way or the other. I'm thinking it shouldn't get too much worse as I assemble/disassemble, but cable ties are cheap and stiffens everything up pretty nicely
- Ergo tested using 50 percentile human model in CAD, then validated using crappy makeshift representations.
Hero shot
Click to view full size!
Unpainted
Click to view full size!
All parts laid out
Click to view full size!
My friend in it
Click to view full size!
Click to view full size!
Its still quite heavy but it does the job (transporting it in it's scaffolding is about 10 kilos, and 15 with some special scaffolding which was left over from the laser cutting which keeps everything secure). The biggest problem I have is that the front section is too light at the base so I have to weigh it down with a phone book and using cable ties.
Its made of 9mm MDF, laser cut. I've tried to FEA the seat base plate to optimise it a bit but as far as I know, the webbing is in the right directions (working on tension rather than compression). There aren't any internal sharp corners just in case stress concentrations happen to be an issue. Really the bigger problem is with perception: its making people scared they'll break the crap out of it if they touch it.
I've already started on 'V2', looking to really just stiffen that front section somehow. I'm thinking of designing a new one for manufacturing (low numbers) which I think I'll sell to my friends who were interested for about $200-300, or about $100 on top of manufacturing. The next design should have a stiffer front section, a spot to put a spot for the H-shift (and maybe design a handbrake module). Depends if I can get my hands on the Fanatec wheels for GT5. Also slightly more elegant cable management.
The lessons I learnt for this type of stuff is to make sure you get your ergo right before committing to anything (or put in adjustability). I got the driving height perfect in my mind (which makes it really nice), but the height from the seat to the ground is a bit low so its hard to get in and out. Really didn't think about that. It pays of to validate your ergo before you commit to anything.
Hope this helps someone! And thanks to everyone who contributed to this forum. I pulled heaps of ideas while designing this. Theres some pretty cool stuff happening here.
👍
