SimXPro 40x40 Profile: Where to Use It in a Rig Build
By SimXPro l Sim Racing Shop | Published: 2026-11-01
Category: Tips & Care
Learn where the SimXPro 40x40 profile fits best in a sim rig build, from accessory mounts to bracing, plus cutting and fitting steps that avoid common mistakes.
Quick answer
Use the SimXPro 40x40 profile for light-duty structure and accessory mounting: shifter arms, button box brackets, pedal heel plates, and secondary bracing. Avoid it as the main base or upright material for a high-force direct-drive setup, where larger profiles do the heavy lifting.
Where 40x40 earns its place, and where it does not
A 40x40 extrusion is the smallest common building block in a sim rig. That makes it ideal for parts that carry little load but need to be stiff and adjustable, such as a shifter mount, a handbrake plate, or a bracket for a button box. It is also useful as secondary bracing between larger profiles, where it stops panels and accessory arms from flexing without adding much weight.
It is the wrong choice for the main wheel deck uprights, the pedal deck base, or the central spine of a cockpit that will see strong force feedback. Those parts need the larger profiles already used in SimXPro rigs, and substituting 40x40 there is a common cause of flex and creaking. Treat 40x40 as a supporting actor, not the lead.
Plan cuts around the profile length options
The SimXPro 40x40 Profile is sold with Color and Length options, so you can order the length that matches your design rather than cutting everything from one long piece. Measure each run twice, including the space taken by corner brackets and connector plates, before you choose lengths. A cut that is 5 mm short can often be saved with a slotted bracket; a cut that is 5 mm long usually cannot.
Step-by-step: cutting and fitting 40x40 profile
- Map the load path before you cut: Sketch the rig and mark which runs carry wheel force, pedal force, or seat load. Assign 40x40 only to runs that carry accessory weight or act as secondary bracing; leave primary structure to larger profiles. If a run sits between the wheel base and the floor, it is probably not a 40x40 job.
- Measure inside-to-inside, not outside-to-outside: When fitting a 40x40 between two larger profiles, measure the clear gap and subtract the thickness of any corner brackets or connector plates. Write the final cut length on the profile with tape before cutting. A test fit with the brackets loosely assembled catches most length errors before the saw comes out.
- Cut square and deburr both ends: Use a fine-tooth blade for aluminium and check each cut against a square. File or deburr the cut ends so brackets sit flat and the profile slides cleanly into slots. A cut that is visibly out of square will pull the whole accessory arm out of alignment.
- Assemble loose, then tighten in sequence: Slide in T-nuts and brackets before final tightening. Snug all fasteners first, check that the accessory sits at the intended angle, then torque in a cross pattern so the profile does not twist. Tightening one end fully before the other is the most common cause of a twisted 40x40 arm.
- Check for flex with the accessory loaded: Fit the shifter, button box, or heel plate and apply realistic force by hand. If the 40x40 run flexes visibly, add a second brace or move that load to a larger profile rather than over-tightening the brackets. Over-tightening a small profile to cure flex usually dents the slot and makes future adjustment harder.
Product facts
- SimXPro 40x40 Profile: Powder-coated black aluminium profile with a 30% matt finish, available in selectable lengths and colors. The coating resists scratches better than standard anodized profiles, which matters on accessory arms that get knocked during adjustments.
SimXPro 40x40 Profile
