DCOW Template

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT
Building Plans for the
DCOW
(Dark Chest of Wonders)
Racing Rig
Design, CAD-Model, Drawings and Prototype done by

Timo Reichensperger aka DerKaffeemann
This plans are meant to complete my DIY guide on InsideSimracing.tv

Check out my DIY topics there for photos and additional building instructions!
Not for commercial use!
Building Plans for the
DCOW
Racing Rig
Preamble:
Page 1: Cover
I created the DCOW Rig to fulfill several requirements: The

rig should be able to tuck away all my gear nicely and it
should have the smallest possible footprint. At the same
time it should look nice and should be solid as a tank.
I was inspired by the RaceStar Converttable but I tried to
do a much simpler and cheaper approach.
So I did a whole new design from scratch that should be
easy to be built with my limited capabilities. That outcome is
what you see here.
Page 2: Index page, Preamble

Page 3: Info to start with
Page 4: Complete Rig in closed position, Overview
Page 5: Complete Rig in open position, Overview
Page 6: Closed position, Cross-sectional views (with part numbers)
Page 7: Main Housing assembly, Overview
Page 8: Main Housing Part 1
Page 12 Seat Unit assembly, Overview
Page 13: Seat Unit Part 1
I would be happy if you follow the build and do a similar rig

and I'll be happy to answer some further questions on
insidesimracing.tv. Of course you'll do the build on your own
response and I will not take any response for the outcome
or for financial or physical damage that may occur. At the
same time I want to point out that I'm the legal owner of
the idea, design and footage of the DCOW rig. So you aren't
allowed to use this documents commerically directly or
oblique.

Page 17: Wheel Deck assembly, Overview
Page 18: Wheel Deck Part 1
If you like this documentation it would be fair to donate a

few bucks to me.
Just contact me via youtube (DerKaffeemann123)
or InsideSimRacing.tv (DerKaffeemann).

Page 21: Pedal Unit assembly, Overview
Page 22: Pedal Unit Part 1
Page 23: Additional Parts - Small Parts
Thanks in advance.
Best Regards,
Timo Reichensperger
aka DerKaffeemann
Page 24: Additional Parts - Lid
INDEX:
INFO to start with:

Most likely you've downloaded this documentation after having a look at my "DCOW Racing Rig" on insidesimracing.tv and now you probably want to do a similar rig.
If that's the case and if you read my story there thoroughly, you should have a good idea what it takes to complete a similar build.
If you haven't seen the real rig yet, you should check my DIY-thread on ISR first and foremost (search for "DerKaffeemann", "DCOW" or "Dark Chest of Wonders").
You need the following tools and means:

- a power drill with some drill-bits
- a saw for wood (a manual saw will work but a circular saw or electric hacksaw will make things easier)
- a long piece of metal or wood that you can use as a ruler
- a folding rule or other kind of measuring device
- tap and die for the aluminum mounting plate
- optionally a saw for metal (in case you need to cut down the mounting plate)
- some screwdrivers and screws
- a file to trim the mounting plate
- some sheets of sandpaper
- wood glue
- optionally hammer and nails
Tips for the wood:
Luckily in german hardware stores you usually can order the pieces cut right to the milimeter without a price-adder to the price per square meter. If you ask your wood supplier
kindly he will most likely cut all the the rectangular for you spot-on, too. So for the pieces that aren't rectangular, just think of a square piece that the part fits in. So in the
end you would only need to do some diagonal cuts and there you are. Just have a look at the drawings and write down what pieces you need.
I chose MDF for my rig because it is cheap, heavy and rather durable while being really easy to work with. You have to keep some things in mind when you work with MDF, though:
MDF is strong only in the length direction. Its front sides are so weak that they barely hold a screw. You might accidentially split the board in half if you put nails or srews in
the face side without pre-drilling. There's an easy trick to reinforce the face sides a bit, though. I recommend you to do the following:
Sand all the face surfaces gently with a rather fine sandpaper and deburr the edges (adding small radii will help to strenghten the face side edges). Then wipe the dust off with a
fuzz-free rag and prepare a brush and a dispensable plastic cup. Pour a good sip of your (water-bases) wood glue in the cup and then delicately thin it down with some water
(you don't need much). You should end with a consistency like coffee cream. Aplly this diluted wood glue to all the face side surfaces with a brush. Let it dry and then gently sand
the sides a bit again. You should notice that the glue was sucked in and hardened the face sides.
You could use such deluted glue on every surface but keep in mind that the water will upwell the small fibres in the wood and you'll end with a slightly rough finish.
Now get to work:
Read my DIY topic and have a look at all all the drawings again. Take measurements of your seat and hardware and make some thoughts about if you might need to change some
dimension. As soon as you are certain with the dimensions you can buy the wood and small parts. Cut the pieces down to size, invite a friend or relative and start building... Have
fun and share your outcomes...
To make a long story short:

I created the CAD-model of my DCOW Racing Rig after getting a lot of positive response for the real one and after receiving many requests for plans of it. Thank you for
encouraging me to stay the course. Now I want to encourage you in return. If you are able to hold a hammer and if you have a minimum of tools, you should easily be able to
follow the build. I pulled the whole project off in a small appartment and in a tiny cellar room. I had no special tools available and was forced to improvise most of the time. To
cap it all, I was short on a budget. So if you are in a similar starting situation, you will be able to pull this off!

5
582 mm [22,92 in]
610 mm [24,02 in]
1183 mm [46,59 in]

Design Plans for the
DCOW
Name: DCOW ASSEMBLY
Racing Rig
Design, prototype, model

and drawings created by:
Timo Reichensperger
aka DerKaffeemann
Scale:
Sub-Assembly: none
Part Number: 1
Feedback will be appreciated.
Copyrights reserved.
Page:
4
Material: unspecified
A2
Always use your safety equipment. Handle tools with care!
Use this plans on your own risk! Have fun!
2
1

5
1060 mm [41,74 in]
826 mm [32,51 in]
1180 mm [46,45 in]

1814 mm [71,42 in]
DCOW
Name: DCOW ASSEMBLY
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Sub-Assembly: none
Part Number: 1
(1:5)
Page:
A2
2
1

5
C-C ( 1 : 5 )
A-A ( 1 : 5 )
F
582 mm [22,92 in]
D
B
3
B-B ( 1 : 5 )
600 mm [23,62 in]
1180 mm [46,45 in]
DCOW
Name: DCOW ASSEMBLY
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Sub-Assembly: none
Part Number: 1
Page:
6
A2
2
1
The exact position of the Mounting Plate

1.4 should be determined AFTER a rough
assembly. So don't care about it, yet!
1.4
F
Part 1.1
(432 mm [17,01 in])
Part 1.2
81
(906 mm [35,67 in])
1180 mm [46,45 in]
568 mm [22,36 in]
600 mm [23,62 in]
(528 mm [20,79 in])
Part 1.3
Tips for the assembly:
- All the dimensions were made to ensure a tight fit with my racing chair (extreme space safing approach)!
With a different chair, wheel and pedal set you might need other measurements!
- Assure that the Back Plate (1.3) and Floor Plate (1.2) are identical in width
- For the main assembly, the other dimensions are not critical
- Use wood-glue on the face sides of the Floor Plate (1.2) and Back Plate (1.3)
- Allign the parts properly and secure them with some additional screws or nails
- Always predrill for nails and screws to prevent the face sides of the wood from splitting
8
DCOW
Name: Main Housing
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Sub-Assembly: none
Part Number: 1.1
(1:5)
Page:
Material: MDF or similar

A2
2
1
(1090 mm [42,93 in])

D
565 mm [22,24 in]
81
302 mm [11,88 in]
377 mm [14,86 in]
453 mm [17,85 in]
16 mm [0,63 in]
B
1180 mm [46,45 in]
- I wouldn't recommend to do a cut-out logo and would rather go with some stickers.
- If you chose to do a cut-out logo, make sure it is not too big since
we need some "meat" for the Mounting Plates.
- If you do a cut-out logo you should back it with some plexiglass. This will avoid dust
from getting into the chest.
You'll need two of the shown part...
6
DCOW
Name: Side Panel
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Page:
Sub-Assembly: Main Housing

8
(1:5)
Material:
16
mm
MDF
Part Number: 1.1
A3
3
2
1
274 mm [10,80 in]
1140 mm [44,88 in]
22 mm [0,87 in]
568 mm [22,36 in]
A
B
B
R3
mm
[0,1
2i
n]
A(1:2)
in]
2
[0,1
m
m
This side faces towards the seat.
R3
A big radius here prevents the
edge from chipping!
DCOW
Name: Floor Plate
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Page:

(1:5)
9
Material:
22
mm
MDF
Part Number: 1.2
A3
3
2
1
565 mm [22,24 in]
50 mm [1,97 in]
Feel free to add a hole here

to fit a grommet for cable routing!
284 mm [11,18 in]
16 mm [0,63 in]
568 mm [22,36 in]

B
B
This dimension has to be equal to the
with of the Base Plate
DCOW
Name: Back Plate
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Page:

(1:5)
10
Material:
16mm
MDF
Part Number: 1.3
A3
3
2
1
)
in]
12
mm
47
,
0
[
)
in]
40 mm [1,57 in]
C
90 mm [3,54 in]
130 mm [5,12 in]
60
X
mm
1,3
20 mm [0,79 in]
(M10)
90
B
Tap holes with a thread size of your choice.

Keep in mind it must fit the mounting screw!
Of course you'll need only one threaded hole.
A second one could become handy for
modifications on the Wheel Deck...
Dip the threaded holes to easen the assembly and
to avoid damage on the sides of the Wheel Deck!
The 4 outer holes are for

wood screws. Choose the size
of the hole and the dip
according to the screw you
intend to use.
Name: Mounting Plate
Add a big chamfer to the sides to easen the

assembly and to avoid damage on the sides of the
Wheel Deck!
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:

6
DCOW
Page:

(1:1)
11
Material:
20x60
Aluminum
Part Number: 1.4
A3
3
2
1
mm
24
,
0
[
60 mm [2,36 in]

5
540 mm [21,26 in]

F
F
The overall dimensions of the seat
are critical for the whole build.
So you have to invest some brain power
to adjust the measurements since your
seat will have different dimensions!
1060 mm [41,74 in]
2.2
2.4
9 mm [0,37 in]
81
141 mm [5,55 in]
2.1
533 mm [20,99 in]
704 mm [27,70 in]
C
2.3
The Seat Lid has some overlap. This
is neccessary to level the Seat Lid
with the Base Plate
B
Place hinges (Part 8) here
Name: Seat Unit
DCOW
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Sub-Assembly: none
Part Number: 2.0
(1:5)
Page:
12
A2
2
1
C
(432,7 mm [17,04 in])
16 mm [0,63 in]
450 mm [17,72 in]

B
DCOW
Name: Seat Side Panel
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Sub-Assembly: Seat Unit

Part Number: 2.1

6
(1:2)
Page:
13
Material: 16mm MDF

A3
2
1
109 mm [4,29 in]
81
460 mm [18,11 in]
480 mm [18,90 in]
You'll need to add several

holes here to mount your
seat rails
16 mm [0,63 in]
A
(457,5 mm [18,01 in])
A(1:1)
81
DCOW
Name: Seat Base
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
To be able to glue all the parts together tightly, you'll need to follow the right angle

Part Number: 2.2
(1:5)
Page:
14
Material: 16mm MDF

A3
2
1
566 mm [22,28 in]
This plade will slide between the Side

Panels of the Main Housing. So keep it a
little smaller than the inner dimensions
of the Main Housing
C
548 mm [21,57 in]
16 mm [0,63 in]
A
B
(545,5 mm [21,48 in])
A(1:1)
DCOW
81
Name: Seat Floor
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:

Part Number: 2.3
(1:5)
Page:
15
Material: 16mm MDF

A3
2
1
610 mm [24,02 in]
16 mm [0,63 in]
548 mm [21,57 in]

B
,0
R1
mm
04
[0,
in]
Add a big radius to prevent the edge from splitting.

This edge will have to support all the weight of the
seat and the driver.
When the Chest is closed, this part will be right lid.
DCOW
Name: Seat Lid
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:

Part Number: 2.4
(1:5)
Page:
16
Material: 16mm MDF

A3
2
1

5
The original design was made for a Fanatec 911 GT2 wheel.
Now I've mounted a Fanatec CSW to it without a problem.
F
F
If you want to mount another brand of wheel
you might have to amend the dimensions a bit...
526 mm [20,71 in]
Through this hole you'll put the mounting screws

to secure the Wheel Deck in upright position
3.1
3.2
This bevel is just for the looks

So keep it or leave it away...
Add hinges (Part 8) here to attach

the Wheel Deck to the Main Housing
522 mm [20,55 in]
190 mm [7,48 in]
3.3
B
DCOW
Name: Wheel Deck
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Sub-Assembly: none
Part Number: 3.0
The width should be equal to the inner dimension

between the two mounting plates in the Main Housing

(1:5)
Page:
17
A2
2
1
510 mm [20,08 in]
465 mm [18,31 in]
This two dimensions

aren't critical. Just
leave enough room for
your legs and keep in
mind that the free
space must be big
enough to fit your
pedals in!
45 mm [1,77 in]
16 mm [0,63 in]
400 mm [15,75 in]
490 mm [19,29 in]

DCOW
Name: Wheel Deck Support
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Page:
Sub-Assembly: Wheel Deck

18
(1:5)
Material:
16mm
MDF
Part Number: 3.1
A3
3
2
1
75 mm [2,95 in]
510 mm [20,08 in]
310 mm [12,21 in]
390 mm [15,35 in]
16 mm [0,63 in]
50 mm [1,96 in]
190 mm [7,48 in]
DCOW
Name: Wheel Deck Side
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
A
6
Page:

(1:5)
19
Material:
16mm
MDF
Part Number: 3.2
A3
3
2
1
66
10 mm [0,39 in]
This hole must fit your
mounting screw in size
and position
Add holes according to the drill pattern of your wheel.

ATTENTION: Fanatecs drill pattern is off-center
So it's critical not to flip it over accidentally!
190 mm [7,48 in]
16 mm [0,63 in]
C
522 mm [20,55 in]

Guess what, the width should be equal to the
inner dimension between the two mounting
plates in the Main Housing (or slightly
narrower)
DCOW
Name: Wheel Plate
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Page:

(1:5)
20
Material:
16mm
MDF
Part Number: 3.3
A3
3
2
1

5
Obviously this is a set of Fanatec CSPs.

Big thanks to Fabian Gundermann!
He provided the awesome 3D-model of the pedals!
195 mm [7,67 in]
4.1
Mount the Pedal Plate on a set of Seat Rails.

The pedal position then could be adjusted
for perfect ergonomics (and for guest drivers)
26 mm [1,03 in]
The Pedal Assembly was made to fit a set of Fanatec Clubsport Pedals.
For different pedals you might have to adjust the measurements!
360 mm [14,17 in]
I pass on giving dimensions for the boreholes.

If you managed to follow the build to this point,
it shouldn't be a challenge anymore!
DCOW
Name: Pedal Unit Assembly
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
350 mm [13,78 in]
Sub-Assembly: none
Part Number: 4.0
(1:2)
Page:
21
A2
2
1
350 mm [13,78 in]
Place holes according to

the drill patern of your
pedal set and seat rails...
C
16 mm [0,63 in]
360 mm [14,17 in]

B
DCOW
Name: Pedal Plate
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Page:
Sub-Assembly: Pedal Unit Assembly

(1:5)
22
Material:
16mm
MDF
Part Number: 4.1
A3
3
2
1

5
45 mm [1,75 in]
Part 7
30 mm [1,18 in]
3 mm [0,12 in]
Part 6
14 mm [0,55 in]
Part 5
M10
36 mm [1,42 in]
60
mm
[2,3
6i
n]
Sketch of the Lid Hinge

You'll need two of it...
56 mm [2,20 in]
Sketch of the Mounting Screw

You'll need two of it...
Sketch of the Glide-Foot

You'll need four of it...
Part 8
All those small parts can be found in a hardware store.

If you can't find similar parts you just need to be creative.
Additionally you will need:
46 mm [1,81 in]
- several screws or nails

(short ones that don't pierce through the wood plates)
- wood glue
- paint or adhesive foil for the surface finish
- carpet or beadspread for the floor and inner walls
Optional:
240 mm [9,45 in]
double sided duct tape to glue some carpet to the hinges

plexi-glass to back up your cut-out logo
a grommet for the cable routing
some washers for your Mounting Screw
Sketch of the Seat Assembly Hinge

and Wheel Deck Hinge
You'll need four of it...
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Sub-Assembly: none
Part Number: several
DCOW
Name: Small Parts
Page:
23
A2
2
1
550 mm [21,65 in]
16 mm [0,63 in]
Place Lid Hinges (Part 5) here
B
610 mm [24,02 in]
Name: Lid
DCOW
Racing Rig

Timo Reichensperger
aka DerKaffeemann
Scale:
Sub-Assembly: none
Part Number: 5
(1:5)
Page:
24
Material: 16mm MDF

A3
2
1

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VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

Building Plans for the

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

Design, CAD-Model, Drawings and Prototype done by

This plans are meant to complete my DIY guide on InsideSimracing.tv

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

Building Plans for the

I created the DCOW Rig to fulfill several requirements: The

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

Page 2: Index page, Preamble

I would be happy if you follow the build and do a similar rig

Page 15: Seat Unit Part 3

If you like this documentation it would be fair to donate a

Page 19: Wheel Deck Part 2

Page 24: Additional Parts - Lid

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

INFO to start with:

You need the following tools and means:

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

To make a long story short:

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

582 mm [22,92 in]

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

610 mm [24,02 in]

1183 mm [46,59 in]

(Dark Chest of Wonders)

Name: DCOW ASSEMBLY

Design, prototype, model

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

1060 mm [41,74 in]

826 mm [32,51 in]

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

1180 mm [46,45 in]

Design Plans for the

(Dark Chest of Wonders)

Name: DCOW ASSEMBLY

Design, prototype, model

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

582 mm [22,92 in]

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

600 mm [23,62 in]

1180 mm [46,45 in]

Design Plans for the

(Dark Chest of Wonders)

Name: DCOW ASSEMBLY

Design, prototype, model

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

The exact position of the Mounting Plate

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

(432 mm [17,01 in])

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

VON EINEM AUTODESK-SCHULUNGSPRODUKT ERSTELLT

(906 mm [35,67 in])

1180 mm [46,45 in]