Playseat challenge - Simagic P500 mount - Universal

Pedal mount designed for the Simagic P500 and Playseat challenge. Although this was designed for the P500, it is generic enough that it can fit most pedals with at least two mounting holes. 

For the P500 you should probably print 4 sets.

This was designed to fit with the foam wrapper, so you don't need to cut it. The design is parametric however, so you can easily change that dimension to fit the pipe only.

Also, if you are printing this for any load cell pedal, I'd highly recommend reinforcing the pivot thingy that holds the seat and the pedal tubes together.

Disclaimer: This was my first time designing something from scratch and not following a tutorial, and although it works, assembly can be a bit of a pain and there are lots of things to be improved (see the end of the description). This means: print at your own risk. =)

Also, never mind the print quality in the pictures. These were from the “prototype” and I am also fighting with my printer to get more speed and there's some quality issues I still have to work through, but the print is working anyway. =)

Hardware (each set):

• 6 - M5 x 45mm socket screws
• 6 - M5 nuts
• 1 - M8 nut
• 1 - M8 x 35mm countersunk screw (the one that comes with the P500 isn't long enough)

You can change the M8 stuff in the model file if your pedal uses different hardware (details in the params list below).

Please note that the hardware list is for each set, so if like me you print four sets, you will need to multiply that by 4. 

Print details:

• Printer: Ender 3 v2 neo + nebula pad (kliper)
• Perimeter: 4 lines
• Top and bottom layers: 5
• Line Width: 0.40mm
• Material: PLA +
• Infill density: 30 (you can probably get by with less, but might have to increase perimeter and top/bottom layers)
• Infill pattern: Cubic
• Position: with the inset for the tubes facing up
  • Not sure it makes any structural difference but the print should look better this way.

Parameters (unit: mm):

• Width: 100
• Height: 50
• Depth: 50
• TubeDiameter: 28
  • This is 1mm smaller than the tube with the foam pad. 
  • If you want to cut the foam, you should use 19.
• TubeDistanceFromEdge: 35
  • This is how much space will be left to one side of the tube. If you don't want to increase the size of the block, you can shift this around to suit your pedal needs.
• BlockFillet: 2
  • Just to round the outer edge so that there's no sharp edge.
• HoleFillet: 0.5
  • Same as above but for the tube. I wanted to leave more surface area there, so that's why it's much smaller.
• ScrewDistanceFromEdge: 6
  • This is what position the M5 mounting screws relative to the edge of the block
• M5NutDiameter: 8.7
  • Should probably be 8.6 or even 8.5 for a tight fit.
• M5NutHeight: 4.5
  • This leaves the nut (the one I have, at least) flush with the block's face
• PedalNutSlotWidth: 13.5
  • This is the width for the M8 nut that seats in between the two parts.
  • If your pedal uses a smaller nut/bolt combo, you can change this to accommodate it. 
  • You can also use this to mount a hex head bolt from this side and the nut on the outside depending on your specs.
• PedalNutSlotHeight: 7
  • This is the height of the slot for the nut above.
• PedalScrewDiameter: 8.5
  • Diameter of the screw (M8 in this case) for the pedal mount.
  • In combination with PedalNutSlotWidth and PedalNutSlotHeight, you can change this to accommodate a smaller screw/nut combo. Like the M6 present in a lot of pedals.
• ScrewSlotLenghtFromCenter: ( Width / 2 ) + ( ScrewDistanceFromEdge * 2 )
  • This is how wide the M8 screw slot is length wise. 
  • Can't remember now how I got that “formula”. I was a couple of beers in at that point. There's probably a better way to figure that out. =P
• ScrewSlotHeight: Height * 0.70
  • This is the height of the slot for the pedal mounting screw (M8 in this case).
  • I made it so it is present on both sides so it can accommodate longer screws. 
  • It's not supposed to be precise. I've done it by “feel”and similar to the other screw slot, there were beers involved. 

Things I would change (I am not, but you can =P):

• Improving assembly:
  • Reduce the M5 nut recess by a hair to make it more of a tight fit
  • Flip the M5 screws and nuts around so you can screw from the bottom with the pedal mounted.
• Print speed and quality of life improvements:
  • Take out about 4mm from both top and bottom
    • This will make it faster to print and I don't think it will significantly decrease its strength.
    • If you change the large hole to fit the pipe without the foam, I'd consider taking 8 to 10mm from both top and bottom (I didn't test this).
• Make the M5 screws dimensions parametric. 
  • Currently it's a bit of a pain to change it if you want to change the height or type of screw.
• Overall design improvements:
  • For the M8 nut slot, I'd also add it to the top of the large hole for the playseat “tube". This would make it even more generic and fit a larger range of pedals.
    • If that is done, the M8 screw would need to be significantly smaller, tho.
  • Increase the width by around 5 or 10mm (in the smaller side beside the large hole)
    • This would allow for a better fitment of the m8 nut on that side so that it isn't really jammed against the tube.