Aluminium Extrusion Profiles for Sim Rigs: What They Are & How to Use Them
By Racing Simulators - World's Best Sim Rigs | Published: 2026-10-28
Category: How-to Guides
Learn what aluminium extrusion profiles are, how they work in sim rigs, and practical ways to use 40x80mm profiles for customizing or reinforcing your cockpit.
Quick Answer
An aluminium extrusion profile is a T-slot aluminum beam used to build or modify sim rigs. The 40x80mm profile with an 8mm slot is a versatile spare part for extending frames, adding mounts, or reinforcing weak points.
Why the 8mm Slot Matters
The 8mm T-slot is the standard size used in most sim rigs, meaning you can reuse the same nuts, bolts, and brackets you already own. This makes the 40x80mm profile a drop-in solution for most cockpits without needing new hardware.
A 40x80mm profile offers high rigidity in one direction while remaining relatively lightweight. This makes it ideal for adding length to the main chassis or creating sturdy supports for heavy components like direct drive wheelbases or large monitors.
Common Uses in a Sim Rig
Beyond extending the frame, these profiles are often used to build custom mounts for shifters, handbrakes, or button boxes. You can also reinforce flex-prone areas by adding diagonal or cross braces, which is a popular upgrade for rigs with a lot of leverage.
Frequently Asked Questions
- What sizes of aluminium extrusion are used in sim rigs?
- The most common profiles are 40x40mm for general framing and 40x80mm for heavier loads or longer spans. The 40x80mm profile offers more rigidity along its wider axis, making it a good choice for reinforcing or extending the main chassis. Measure your existing slots and hardware before buying to ensure compatibility.
- How do I attach components to an 8mm slot extrusion?
- Slide T-nuts into the slot, position them where needed, and secure with bolts. Always use a washer to distribute load and avoid over-tightening, which can strip the slot. Keep a few spare T-nuts and bolts on hand for quick adjustments.
- Can I cut an aluminium extrusion profile to a custom length?
- Yes, you can cut it with a miter saw or hacksaw. Deburr the cut edges with a file to remove sharp burrs and ensure smooth sliding of T-nuts. Always deburr after cutting to avoid damaging nuts or your hands.
- How do I extend my sim rig frame using a 40x80mm profile?
- Attach the profile to the existing frame using corner brackets or plates, aligning the slots so you can slide in T-nuts across the joint. Use at least two brackets per connection for stability. Check the alignment with a straightedge before fully tightening.
Product Facts
- 40 x 80mm 600mm Aluminium Extrusion Profile, 8mm Slot – Set of 2: This 40x80mm profile is cut to 600mm length, has an 8mm T-slot, and comes in a black anodised finish. The 600mm length suits many rig extension points, and the black anodised coating resists wear while matching most cockpit aesthetics.
40 x 80mm 600mm Aluminium Extrusion Profile, 8mm Slot – Set of 2
