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

Rider height (in)

Results

Side rail: 47 in
Crossmember: 19 in
Upright: 27 in
Pedal rail: 16 in
Total profile: 269 in
Pieces: 12

Related gear

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. 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.

Disclaimer — no professional advice, no liability

These calculators are simplified estimates for planning a sim rig. They are not a structural sign-off, a wheelbase torque limit, or a guarantee that a quick release, profile or headset will fit. Check the hardware before you cut aluminium or bolt a base down.

These calculators, pages and any related content are provided “as is” and “as available”, solely for general educational and informational purposes. They are simplified mathematical estimates, not a structural sign-off for a rig, a wheelbase torque limit, a quick-release compatibility certificate or a professional seating setup.

Results can be wrong, incomplete or inapplicable to your wheelbase, wheel, pedals, screens, headset or aluminium profile. You must independently verify every figure, assume all risk, and confirm the profile, the bolt pattern and the torque printed on the part before you cut or tighten anything.

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