What is 80/20 Aluminum Profile?

Modular aluminum extrusion system with T-slot channels, used to build rigid, customizable sim racing cockpits. Named after the common 80mm x 20mm cross-section.

80/20 Aluminum Profile

80/20 aluminum profile (also called aluminum extrusion, T-slot, or simply "8020") is a modular construction system used to build sim racing rigs. The name comes from a common cross-section size: 80mm x 20mm, though many sizes exist.

What Is 80/20?

80/20 consists of aluminum bars with T-shaped slots running along their length. These slots accept special nuts and bolts, allowing you to connect pieces at any angle and adjust positions infinitely.

Think of it like adult LEGO for building structures—except the result is rigid enough to handle high-torque direct drive wheelbases without flex.

Why Sim Racers Use 80/20

Rigidity: Properly assembled 80/20 rigs have zero flex. This matters because wheelbase torque needs something solid to push against.

Adjustability: Everything can be repositioned. Wheel angle, pedal distance, seat position—all adjustable without new parts.

Upgradability: Start basic, add components later. Triple monitor mounts, button boxes, keyboard trays—it all bolts on.

Durability: Aluminum doesn't rust, warp, or degrade. A well-built 8020 rig lasts indefinitely.

Customization: Build exactly what you need. No compromises for mass-market appeal.

80/20 Profile Sizes

Size	Common Use
40x40mm (1.5"x1.5")	Light-duty, monitor mounts
40x80mm (1.5"x3")	Main frame, pedal deck
80x80mm (3"x3")	Heavy-duty bases, high-torque setups
20x20mm / 20x40mm	Small accessories, keyboard mounts

Most sim racing rigs use 40x40mm or 40x80mm for the main structure.

Pre-Built vs Custom 80/20

Pre-Built 80/20 Rigs

Companies like Sim-Lab, Trak Racer, and Advanced SimRacing sell complete 80/20 rig kits:

Pros:

Designed specifically for sim racing
All hardware included
Tested compatibility with common equipment
Instructions provided

Cons:

Less customization than fully DIY
Premium pricing
May include parts you don't need

DIY 80/20 Rigs

Build from scratch using profile from industrial suppliers:

Pros:

Complete customization
Potentially cheaper (especially locally sourced)
Exactly what you want, nothing more

Cons:

Requires planning and CAD skills
Sourcing hardware can be complex
No instructions or support
Easy to over-engineer

80/20 vs Integrated Cockpits

80/20 rigs:

Maximum rigidity
Infinite adjustability
Industrial appearance
Higher price floor (~$400+)

Integrated cockpits (Playseat, GT Omega):

Designed appearance
Fixed adjustment points
More compact sometimes
Lower price entry (~$200-$400)

For high-torque direct drive (15Nm+), 80/20 is strongly recommended. For entry/mid-tier wheelbases, either works.

Building Tips

Start with a plan: Measure your space, decide on components, sketch it out.

Order extra hardware: T-nuts, corner brackets, and bolts. You'll need more than you think.

Consider cable management: Plan routing for wheel, pedals, shifter, USB cables.

Budget for seat: A quality seat is as important as the frame. Bucket seats, real car seats, or dedicated sim seats all work.

Popular 80/20 Rig Brands

Sim-Lab: P1-X, GT1 Evo (European, high quality)
Trak Racer: TR8, TR160 (global availability)
Advanced SimRacing: ASR (North America)
RigMetal: Budget-friendly kits

Related Terms

Rig / Cockpit: The complete sim racing structure
Wheel Stand: Simpler mounting alternative
Direct Drive: Wheelbase type that benefits most from 8020 rigidity