SimXPro 40x80 Profile: Uses, Cutting, and Assembly Tips

By SimXPro l Sim Racing Shop | Published: 2026-10-30

Category: How-to Guides

Learn how to use the SimXPro 40x80 profile in your sim rig: practical uses, cutting tips, and assembly steps with common mistakes to avoid.

Quick answer

The SimXPro 40x80 profile is a versatile extrusion for sim rig bases and sturdy supports. Use it for main chassis rails or uprights, cut it with a miter saw and carbide blade, and assemble with T-nuts and corner brackets for a rigid build.

Why 40x80 instead of 40x40 or 40x120?

The 40x80 profile gives you extra strength in one direction without the weight or cost of a larger 40x120. It's ideal for the main horizontal rails of a cockpit where bending forces are highest, while 40x40 works for lighter cross members.

Because the SimXPro 40x80 is powder coated black 30% matt, it resists scratches better than standard anodized profiles. That finish also makes it easier to keep clean, which matters if you move or adjust your rig often.

Cutting: tools and technique

You can cut 40x80 aluminum extrusion with a miter saw fitted with a carbide-tipped blade. A fine-tooth blade (60 teeth or more) reduces burrs and gives a cleaner edge. Always clamp the profile securely and cut slowly to avoid binding.

Measure twice and mark the cut line with a fine marker. For repeat cuts, use a stop block to keep lengths consistent. Deburr the cut ends with a file or deburring tool before assembly to prevent scratches and ensure brackets sit flush.

Assembly considerations

The 40x80 profile has a central slot that accepts standard T-nuts and M8 hardware. Use corner brackets at joints for extra rigidity, especially at the base of uprights. Tighten fasteners gradually to avoid stripping threads in the T-nuts.

If you're building a custom cockpit, plan your cuts to minimize waste. The profile is sold by length, so order slightly longer than needed to account for cutting errors. Always check that your brackets and hardware match the slot size.

Step-by-step assembly guide

Plan your layout and measure: Sketch your rig dimensions and list every profile length you need. Include extra 10-20 mm for cutting errors. Double-check measurements before ordering or cutting. Mistake: cutting without a plan often leads to wasted profile. Checkpoint: verify all lengths against your sketch.
Cut the 40x80 profile: Use a miter saw with a carbide-tipped blade (60+ teeth). Clamp the profile securely, mark the cut line, and cut slowly. Deburr the ends with a file or deburring tool. Mistake: cutting too fast can cause burrs and inaccurate cuts. Checkpoint: deburr every cut end before assembly.
Dry-fit the frame: Assemble the main structure using corner brackets and T-nuts, but only hand-tighten. Check that all corners are square and that the profile ends sit flush against brackets. Mistake: overtightening before aligning can cause misalignment. Checkpoint: use a carpenter's square to verify 90-degree corners.
Tighten all fasteners: Once the frame is square, tighten all bolts in a cross pattern. Use a torque wrench if available, but avoid over-tightening as it can strip the T-nut threads. Mistake: uneven tightening can introduce flex. Checkpoint: re-check tightness after a few hours of use.
Mount your components: Attach your seat, pedal tray, and wheel mount using the appropriate brackets and hardware. Ensure that the 40x80 rails are oriented to resist the main load direction (usually vertical for wheel mounts). Mistake: mounting components before final tightening can cause stress points. Checkpoint: verify that all mounting points align with the profile slots.

Product facts

SimXPro 40x80 Profile: The SimXPro 40x80 profile is powder coated black 30% matt and is up to 20% stronger than many profiles used in sim racing. This means you get a durable, scratch-resistant extrusion that can handle the forces from a direct drive wheel without flexing.
SimXPro 40x80 Profile