Driving simulation Coffee table
Theodore Carlos
Rosmini College
Teacher: Alex Breig
Year 12 Hard Materials
Theodore Carlos designed and constructed a driving simulator cum custom coffee table for this scholarship project that used modelling hard materials and strong visual design to create an entirely unique outcome.
Issue
Theodore and his brothers had recently purchased the Logitech G27 control system for use with driving simulation games. The system comes with steering wheel, pedal and gear stick components but the brothers wanted a more realistic and comfortable experience than when using the system on the family couch.
Theo's mother also had an issue with the control system. "She really disliked having the components set up all around the place, and wanted the lounge to actually look like one," explains Theo.
Research
Theo began researching ways to solve these issues by looking at existing driving simulations online. He found that most market systems were either too expensive or large to meet needs of his clients – his brothers and his mother. However, a DIY solution in an online forum gave him inspiration – the user had created a simulator that fitted entirely within an ottoman, complete with an adjustable seat.
Brief
After consulting extensively with his clients Theo decided that a combined coffee table and driving simulation system would meet the demands of his clients perfectly. As the coffee table would sit in front of the television anyway, this was already an improvement on the ottoman system he had seen. He also planned to entirely customise the interior of the control system, so that it would be as similar to a real driving experience as possible.
Other specifications included that
- The simulator should be as ergonomic as possible to avoid user pain and discomfort.
- The system should be safe to use both as a coffee table and simulator, with materials and design that met these requirements.
- The system should be fully adjustable so that people of any size could use it comfortably.
- The system should function well as a coffee table, fit aesthetically with the existing family lounge and be to his mother's taste.
Design
Theo's research into ergonomics showed that a compact design similar to the cockpits used in Formula one racing would be ergonomic, provide an enjoyable and realistic driving experience and use space efficiently.
Theo looked into existing coffee table designs that might accommodate the internal rectangular box shape required, and also fit with the aesthetic requirements of his brief.
Theo then used Google Sketch up to create a series of coffee table designs for his mother to look over. This consultation brought up a major issue for Theo's designs.
"One word came from my client after seeing my computer rendered sketches: 'coffins,'" Theo says.
Of the six concept sketches Theo produced, his mother preferred those that broke up the 'coffin' shape. This was achieved with design elements such as tapered table legs on each corner or by having the top of the table in an irregular shape with an overhang.
This feedback went into a developed concept drawing that featured a curved overhanging top, which Theo used as a guide through the rest the project.
Modelling
Theo measured his brothers and some school friends to gather a range of different sizes that the simulator should fit. He then created detailed working drawings based on his concept drawing to help model the outcome.
"I designed my model using the software CorelDraw 12 and used the laser cutter to cut the components from 3mm plywood. To test it I used a 1:5 scale so that I could use 'Ergonom', a 1:5 scale replica of an average sized person, so I was able to find the right proportions and sizes for comfort and optimum use of space."
Theo assembled the plywood model with a hot glue gun and also created the top complete with scaled-down Perspex sections.
Theo placed Ergonom in the completed model and saw there was room at his head and feet. This enabled the base of the box to be shorter and more like a standard coffee table size. Theo also noticed that the 3mm plywood bent on the longer sections, so he increased the width proportionally to create more stability in the final product.
Table Construction process – Table top
Theo used a single sheet of MDF for the table top for stability, which he cut to the shape with the table saw. He then cut out the sections for the Perspex inserts with a jigsaw leaving space for adjustment. To get the right fit, Theo had planned to use a router to create a groove in which the Perspex would sit but this proved too clumsy and time consuming.
Theo noticed that another student had a similar issue with their project and had created a slot similar to a groove cut by gluing a separate piece of wood to the main piece. Theo used this method on all the cut-outs then carefully sanded and routed them until the MDF and the added sections were flush.
Theo then used the MDF table top to trace out its shape onto a 3mm thin Kauri sheet. The Kauri was then sawn out, glued and clamped onto the MDF for several hours to dry, giving the MDF a glossy wooden veneer.
Theo then traced the table top onto a sheet of Perspex and cut out the Perspex inserts which he then glued into place, finishing the table top.
Table box
To construct the box Theo started with four macrocarpa legs that would form the corners. These were cut to size and tapered with a table saw to give the slimmed down effect for the table's shape. Theo then used a biscuit joiner to create a strong connection between the legs and the sides.
"For the sides of the box I saved time and resources by using a plywood material with an attached pine sheet at the same thickness as the MDF. This was much cheaper, reduced the need for gluing and didn't need to be veneered."
Theo then did a dry assemble of the components to test for any potential weakness or gaps, and then glued and clamped the pieces into place. Theo measured each corner with a set-square to ensure the box was as square as possible and added triangular corner supports to increase structural strength. Theo traced the bottom of the square onto a piece of 18mm MDF to form the bottom, which he then glued into place.
Construction process – Simulator
Theo now moved onto designing and constructing the simulator setup that would go inside the table. This meant creating an ergonomic interaction between the seat, gear stick, pedal and steering wheel. To save time and avoid complication Theo decided that, like a regular car the gear stick and pedals would be fixed in place but the steering wheel and seat would be adjustable.
Steering wheel
Theo constructed a mount for the steering wheel from MDF that fitted into two wooden rails attached to the side of the box. The wheel mount could then be slid to the most comfortable distance away from the user. Theo created a series of holes and wooden locking pins so that the mount could be easily locked into the chosen position. As the steering wheel came up higher than the sides of the box, Theo had planned for the mount to be taken off and placed into the interior when out of use, but this was seen as too inconvenient. Instead, Theo created a swivelling joint with more locking pins so that the steering wheel mount could be folded under when out of use. This also made the angle of the steering wheel adjustable and significantly improved the ergonomics of his outcome.
Seat
For the seat design Theo had originally wanted to create an entirely foldable and customised seat from scratch, but decided this was an unnecessary complication for the project. Online research revealed that existing custom systems used bucket seats from standard cars but these were too big for the coffee table box. Theo had a stroke of luck at this point when his teacher supplied him with a surplus John Deere tractor seat that fit his simulator perfectly.
Theo then visited his local Pick-A-Part and purchased a seat rail system from an old Mazda. He bolted this to the bottom of the table box and set them exactly parallel to each other.
"I then created a steel rod to go under the rear of the seat. This rod was attached and welded to a plate that sat in the seat rails, providing the needed connection between them and supporting the seat and user's weight combined."
Theo then slotted a circular tube through existing extension holes in the tractor seat. The ends of the tube were then also welded to the plate in the rails. This created a secure yet totally adjustable seat.
With the components complete Theo then carpeted the interior of his simulator to add to the comfort and aesthetic value of his project.
Outcome
Theo's stylish and innovative outcome met the two very different sets of needs of his clients. His pursuit of excellence, high aesthetic values, ingenuity and sheer hard work gained him the Top Scholar award in Technology in 2011.
Download Theo's Scholarship Report (PDF, 15MB)
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