How to Assemble an Aluminium Sim Racing Rig Without Frustration

An aluminium-profile sim racing rig may look complicated when it arrives as separate profiles, brackets and mounting hardware. In practice, the assembly becomes straightforward when the parts are organised and installed in the correct order.

The main advantage of aluminium profiles is that the cockpit does not depend on a small number of fixed mounting holes. The wheel uprights, pedal deck, seat and accessories can be repositioned along the profile channels. This makes the first assembly more forgiving: the rig does not need to be perfectly adjusted before every bolt is tightened.

The best approach is to build the main structure loosely, check that it is square and only then set the driving position. Avoid fully tightening each component immediately. Aluminium cockpits are designed to be adjusted around the driver, so final wheel, pedal and seat positions should be established after the complete frame is standing.

Table of Contents

  • Prepare the components

  • Build the base frame

  • Install the main mounts

  • Set the driving position

  • Add accessories and cables

  • Final checks

1. Organise Everything Before Assembly

Open all packages and group the parts before starting.

Separate:

  • Aluminium profiles by length

  • Corner brackets

  • Bolts and T-nuts

  • Wheelbase mounting parts

  • Pedal-deck components

  • Seat mounting hardware

  • Shifter and accessory profiles

Keep similar bolts together and avoid opening every small hardware bag onto the floor. Aluminium rigs often use several fastener lengths for different mounting points.

Check the profile channels for T-nuts that may need to be inserted before the ends are closed. Some accessories can use roll-in T-nuts later, but planning their approximate position early reduces unnecessary disassembly.

2. Build the Base Frame First

Start with the two long side profiles and connect the front and rear cross profiles.

Leave the bolts slightly loose. This allows the frame to settle naturally on the floor and makes it easier to correct alignment.

Measure the diagonals between opposite corners. If both diagonal measurements are equal, the base is square. A twisted base can make later components appear uneven and may cause the cockpit to rock.

Once the frame is square and sits flat, tighten the main corner connections gradually. Alternate between different corners rather than fully tightening one side first.

3. Install the Uprights, Pedal Deck and Wheel Mount

Add the wheel uprights and position them symmetrically on both sides of the cockpit. Use a tape measure instead of judging their position visually.

Next, install the pedal deck and wheelbase mount. Keep both adjustable at this stage.

SimXPro aluminium cockpits allow the pedal position to be changed in height, reach and inclination. Wheel mounts provide height and tilt adjustment, while models such as the GT-PRO and XT160 also provide wheel reach adjustment.

This modularity is one of the main advantages over fixed steel frames. If you later change the wheelbase or pedals, the mounting position can usually be adjusted without replacing the cockpit.

4. Mount the Seat Before Final Adjustment

The seat establishes the driver’s hip and shoulder position, so it should be installed before the wheel and pedals are finalised.

Side-mounted bucket seats, including SimXPro seats, require the Universal Seat Mount. Different front and rear mounting holes allow the seat height and inclination to be adjusted.

The Universal Seat Slider is useful when the cockpit is shared or when easier access is required.

After installing the seat, sit in the cockpit and adjust:

  1. Pedal distance and angle

  2. Wheel height and reach

  3. Seat inclination

  4. Shifter position

At full pedal travel, the knees should remain bent. The steering wheel should be close enough that the shoulders stay against the seat while turning.

5. Tighten the Rig Only After Testing the Position

Do not assume the first position will be correct.

Sit in the cockpit, press the brake firmly and move the steering wheel through its full range. Check that:

  • The knees do not contact the wheel mount

  • The pedals remain comfortable at full travel

  • The wheel is centred with the seat

  • The shoulders remain supported

  • Entry and exit are not obstructed

Make small adjustments before fully tightening the component mounts.

This is where aluminium profiles are particularly useful. Components can move along the channels in small increments instead of being limited to predefined holes.

6. Add Accessories After the Main Rig Is Finished

Install keyboard trays, mouse trays, shifter mounts and holders only after the driving position is confirmed.

Adding accessories too early can block access to bolts or place a tray where it later interferes with the seat, shifter or cockpit entry.

Useful additions include the Keyboard Tray, Mouse Tray, Headset Holder and PC Tray.

Route cables last. The SimXPro Cable Management Clips allow wiring to follow the profile channels while remaining accessible for future hardware changes.

Why Aluminium Rigs Are Easier to Upgrade

An aluminium cockpit does not need to be rebuilt when one component changes.

The same frame can be adapted for:

  • A different wheelbase

  • Stronger pedals

  • A new seat

  • Shifters and handbrakes

  • Integrated or freestanding monitors

  • Keyboard and mouse trays

  • Haptics or motion systems

Individual profiles and brackets can also be repositioned or replaced. This makes aluminium rigs more suitable for gradual setup development than frames built around fixed mounting points.

Conclusion

The easiest way to assemble an aluminium cockpit is to work from the base upwards and delay final tightening until the complete driving position has been tested.

Build the base square, install the main components loosely, mount the seat and then adjust the pedals and wheel around the driver. Accessories and cable management should be added only after the core setup is finished.

The modular construction may initially involve more individual parts, but it also makes mistakes easier to correct and future upgrades easier to integrate.

Frequently Asked Questions

Should every bolt be tightened immediately?

No. Keep adjustable components slightly loose until the complete cockpit is assembled and aligned.

How do I check whether the frame is square?

Measure both diagonals of the base frame. Equal measurements indicate that the corners are correctly aligned.

Can the rig be adjusted after assembly?

Yes. Aluminium-profile channels allow the main components and accessories to be repositioned later.

Should the seat or pedals be installed first?

Install the seat before making the final pedal and wheel adjustments.

When should cable management be added?

After all hardware positions have been tested and finalised.

Build a Rig That Can Evolve

Explore the complete SimXPro cockpit and accessory range and choose an aluminium-profile platform that can be adjusted around your body, hardware and future upgrades.