Well, after initially wanting to do this back at Uni for my final year project but not being allowed to do it (because is wasn't "Academic" enough), only to then discover a nice seat in the attic of my brother's house a couple of years later when I started working at 3D Scanners UK, I thought that I'd give it another go and to use this seat as part of the racing simulator that I could build......fast forward 4 years and I've finally got round to actually doing it.
So when I first started working at 3D Scanners UK, as a way to learn PolyWorks and to practice using different scanning systems, I thought I'd challenge myself by scanning this seat that I had found from my bothers attic so I could reverse engineer the seat. This was so that I could then import the seat into a CAD package like SolidWorks to design the frame around.....sadly that never happened and the seat has been sat in the corner of my room for the last 4 years. I was also originally going to buy a Fanatec steering wheel setup but I couldn't afford it at the time and then along came another car plus mods and real trackdays which meant that again, the project never took off.
This is the raw scan data using a laser line scanner connected to an articulated arm.
This is the data after it had been meshed to make what we call a polygonal model (a model made up of triangles or "polygons")
And this is after many hours reverse engineering from a scan into a solid CAD model by creating what we call a curve network in a way that it creates 4x4 NURBS patches.
However recently I purchased a Logitech G29 at a pretty low price and after being called out by my friend Darren who is a games designer for Codemasters on the new Dirt Rally game on the Dirt Rally Road Book blog, I thought it was time that I kicked started the project again. So after having scanned my seat, I then set out to scan the Logitech G29 peripherals.
Now I initially started to umm and arh about just buying an off the shelf racing simulator but then it hit me, I've scanned all this stuff....why don't I scan the interior of my 86 so I can get the exact driving position I currently have rather than hope that these off the shelf racing simulators would offer something similar (plus the enjoyment of building one yourself).
So I started to scan the interior of my car, aligned the scans of the Logitech G29 peripherals and the seat to the positions of my interior driving positions, dimensioned up the scans for their positions and angles and then exported all this out into SolidWorks.
Within SolidWorks, I started design the racing simulator using aluminium extrusions and positioned everything in relation to the scans that I had imported. I also had some design criteria that I had to include such as being at a certain height due to the height of my TV and adjustable seat and table top for when I'm not racing.
The design was changed to make construction a lil easier and to generalise some of the parts rather than having lots of unique parts. Not only that, since this is inspired by my 86, the pedals would need to be pointing in the right directions too i.e. hanging upside down rather than pointing up.
After a couple of further minor design tweaks, I assembled the parts together along with modelled up brackets etc so I could easily generate a bill of materials of the required extrusion lengths and quantities, number of brackets, T nuts and bolts, then set out to get prices.
Here you can see the overlap of the original interior scan of my 86 compared to the designed racing simulator that I hoped to build.