Playseat Challenge broken tube repair kit

Playseat Challenge repair kit

So your kids too tried to sit in the Playseat Challenge together? And now the tubes have folder at the hinge point? Yep, we've been there.

This is our 3rd attempt to fix it. Before, we replaced it two times already with a metal tube and drilled a hole in it for the screw at the hinge points. Even filled the tubes with printed ABS cilinders. But the tubes kept breaking. With the clamps in this kit you don't have to drill the holes anymore so the tubes stay more rigid.

Materials needed

• 22mm wooden broom stick of 1m (preferred)
• - OR - metal tube of 1m (22mm outer diameter, at least 2mm wall thinkness)
• 4-6 M3 or M4 screws of 40mm length or longer
• Saw
• Tools
• 4x washer STL printed in ABS or PETG
• 4x clamp STL printed in ABS or PETG

Steps

Step 1: print

• Print the washer 4 times in ABS or PETG
• Print the camp 4 times in ABS or PETG
• Disassemble the hinges on the frame by removing the large screws and the 4 plastic 'shapes' (the black plastic things where each pair clamps a tube)

Step 2: amputate

• In the mean time you can start with the amputation:
  • saw the broken/folded tubes out of the frame (like ~95mm)
  • You will be left with half a chair and a U-shaped part of the frame
• Saw the broom stick or metal tube in two halves of 50cm
• Put these two sticks/tubes in the frame, so the U-part (see diagram)

Step 3: assemble

• Then take two parts of the clamps and screw them together with the broom stick/metal tube in between
  • You can either use M3 or M4 screws, there are different holes
  • Make sure you leave one of the big holes open for the frame to attach. This should be the front bottom holes (so the weight presses down on the screw instead of the weight ‘hanging’)
  • Just look at the photos
• Then on each side use 2 of the 4 plastic ‘shapes’ and two washers, see diagram for the correct order
  • 4 plastic ‘shapes’ will not be used
• Then put in the screw and tighten it with the nut. Not too tight, because it still need to rotate
• Optional but recommended: secure the U-frame with a screw to the broom stick/metal tube

Please like it if you like it and post a make if you made it. Thank you!