CalculatorsAluminium Extrusion Cut List
Aluminium Extrusion Cut List
A profile order is a list of cuts, not a single “rig length”. The reference is a 180 cm driver: 1200 mm side rails, 480 mm crossmembers, 680 mm uprights, 180 mm wheel-deck supports, a 480 mm wheel deck and 400 mm pedal rails.
Inputs
Results
- Side rail
- 47.24 in
- Crossmember
- 18.90 in
- Upright
- 26.77 in
- Pedal rail
- 15.75 in
- Total profile
- 269.29 in
- Pieces
- 12
The Result is indicative and educational. It does not constitute a design, a technical opinion or medical advice and does not replace calculations or verification by a person with the appropriate qualifications and authorisations. Before purchase, installation or use in practice – in particular in electrical installations – the Result should be verified by a qualified specialist. Details: Terms of Service, point 4.
Example products
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- T-slot profile in the length you will actually cut
Order the total, then cut to the piece list. A single 6 m bar is not the same as twelve finished rails.
$100–$400
How the number is made
Scale is height ÷ 180, clamped between 0.85 and 1.15. Each reference length is multiplied by that scale and rounded to the nearest 10 mm. The total is two side rails, three crossmembers, two uprights, two wheel supports, one wheel deck and two pedal rails — 12 pieces.
The clamp stops a very short or very tall rider from scaling the wheel deck into something that no longer holds a base. It does not choose 4040 versus 4080. That comes from the torque and pedal-force tools.
Profile series is not in this list
Every length here can be cut from 4040 or 40160. Pick the series from the wheel torque and the pedal moment, then apply this cut list to that series.
Related calculators
- Direct Drive Torque and Rig Strain
The cut lengths do not tell you whether those rails should be 40 mm or 160 mm deep.
- Sim Seating Position
Height scales the rails. The seating style still sets how upright the seat is on them.
- Pedal Load Cell Rig Stiffness
Pedal rails on this list still have to survive the brake moment.
Questions
Why is 180 cm the reference?
The millimetre list is a common cockpit for that height. Other heights scale it instead of inventing a second geometry.
What happened to the wheel deck in the outputs?
It is inside the total and is cut to the crossmember length, since both start from 480 mm. The two wheel-deck supports are only in the total too: 180 mm at 180 cm, scaled and rounded like the rest. The visible lengths are the ones you measure twice: side rail, crossmember, upright and pedal rail.
Does a 150 cm rider get 0.85 even if the raw ratio is lower?
Yes. Below 153 cm the scale stays at 0.85 so the wheel deck does not shrink without a limit. Above 207 cm it stays at 1.15.