With all adjustment dimensions, steps and ranges definitions out of the way I started nesting the parts and redesigning them for nesting efficiency. Any racing simulator with this many adjustment options (if it existed) would use loads of materials so this was a big task. I’ve been working on it for several days, going back and forth but it’s 90% ready.
This is the current nesting diagram:
I left some room in the first board for other support and accessory parts I still have to add.
The difficulty with nesting and re-shaping is that there are multiple factors you have to consider simultaneously. The main one is that modifying a single part will probably mess up one, or most of the adjustment systems. Then there is making all parts with the least material and waste possible, but there’s also the 1220 x 2440 mm (4 x 8 ft) board size limitation as not every maker has a large CNC machine. Finally, nesting each piece so you can combine materials and make it look even better.
This is how combining two different boards currently looks like:
The first board has the base and all parts that hold equipment: wheel, pedals, shifter and the screen which are mostly horizontal. The second one has all other parts. It’s all-gray looking from the top and all-black from the side.
Still to go:
- Adding a lower horizontal support between the black panels at the front.
- Defining locations for the tower-pc, mouse and keyboard
- Making a more curvy version
- Adapting both versions to 3/4 inch material
- Adapting all plans for Shaper Origin SVG compatibility
- Whatever you guys suggest here!
📅 Update 2021-10-16 – Placed the tower, added some peripheral organizing locations and made an updated 360 animation, check out the new post here.