Cupholders!

[SmithyAtSea]

Hello Everyone,

Just picked up my 2nd Z and both driver and passenger cupholders are broken. The arm that ratchets closed wont lock. Seen plenty of threads on cupholders being broken and there are a few people that are 3D printing parts for them. Took mine out and it looks like they are broken in different parts. One looks like the plastic that touches the teeth is sheared, and the other it still touches the teeth but doesnt hold on the teeth so not sure whats missing here. Sorry if this has been done to death but couldnt find any threads where people posted photos of the inside of the mechanism.

Any help is appreciated,

Cheers Guys.

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Cupholder1.jpg (156.03 KiB) Viewed 1453 times

[Jfgoldfish]

Both of those arms have failed on the same part (the same part that we commonly 3D print replacements for).
The top photo is missing the little plastic plunger that meshes with the 'teeth' as well as two little springs and a small cam.
If all the little parts can be found or cleverly replaced with springs from a ball point pen (that is what I resorted to), those cupholders can easily be repaired.

Worth a shot considering the cost of replacements.

[SmithyAtSea]

i think i have the plunger and the springs. Couldnt tell where the springs came from though. Which part needs replacing exactly? It looks like the part that has sheared runs directly from the main housing, as opposed to being an individual piece.

[Jfgoldfish]

Q6th4.jpg (128.38 KiB) Viewed 1360 times

This bit. This one is also broken in a similar place.

The whole thing needs to be disassembled to fit the new arm. It's not too tricky though. Just a few basic tools required.

[SmithyAtSea]

so i need a full replacement arm on both sides?

[Jfgoldfish]

so i need a full replacement arm on both sides?

Yes, both sides require a replacement arm.

I will have a look if I have any kicking around from when I last 3d printed a few.

Otherwise I am happy to help but only when I restock on black filament. Any other colour will look a little odd!

[SmithyAtSea]

Cheers mate that would be great I appreciate that. Yeah don’t think I could get away with another colour haha. Might get away with red with the red leather though.

[Conrod]

Has anyone by any chance produced STL files for 3D printing the complete assembly? Without having seen the holders in the flesh, I don't know whether they would lend themselves to printing. But if anyone could lend me a complete assembly (even a broken one, if otherwise complete) , I'd be happy to have a stab at designing one in Fusion 360.

I'm currently designing a mount for parking sensors to fit under the front number plate surround on my E85:

http://www.filefactory.com/file/1uovxb9 ... 0Mount.jpg

[Jfgoldfish]

Has anyone by any chance produced STL files for 3D printing the complete assembly?

3D printing something that fits in the same space and serves the same purpose would probably be possible but 3D printing a replica of the BMW one would be near impossible on a hobby machine.

I am picturing a drawer type thing that pulls out manually with some sort of arm similar to the original one. That might work.

3D printing a cup holder that fits on the side of the transmission tunnel is much easier. That's what I designed and used whilst I fixed my driver's side cup holder.

Where are you located? I would consider lending you my passenger side cup holder for the sake of trying! I would even give the printing a go.

[Conrod]

I'm in Didcot near Oxford. As it happens, my latest printer is pretty close to a professional machine. I managed to pick up an e3D BigBox printer last December for £150 - those machines were over £1000 new, and I was surprised at some of the design flaws made by a leading company like e3D (who are located about 15 miles from me). So my "lockdown project" was to strip it right down, add a 2020 extrusion frame to make it more rigid (retaining the original perspex frame as an outer case) and convert it to a CoreXY. It's now a pretty awesome machine - and fast too! I've made quite a few specialist parts now, and am pretty handy with Fusion 360. The only part of the cupholder that shows is the front plate - and my thinking is that the current blanking plates could be used for the front face rather than a 3D printed part with the inevitable layers or small blemishes.

I had a similar idea to you in terms of an alternative design that fits in the tray at the rear of the transmission tunnel, especially as the OEM ones don't seem to be particularly good! But I like a challenge...

[Jfgoldfish]

As it happens, my latest printer is pretty close to a professional machine.

That's one hell of a deal you have picked up there.
E3D make some great kit.

You will be in for a serious challenge though. It is still an FDM machine and will achieve prints of similar quality to any well tuned hobby printer. The key will be creating a design that is tolerant to a little inaccuracy.
I am keen to see what you manage to create.

Some parts of the BMW design would be far easier to manufacture on an SLS, SLA or, better yet, polyjet machine.

[Conrod]

Hmm - I've just watched a video of a cupholder being removed, and you're probably right. I use PETG pretty well exclusively these days, but the biggest problem with it is supports, which often prove to be very difficult to remove. I therefore tend to design and orientate parts to minimise the need for supports - but those holders look as though quite a few of them would be required!

[Robbo82]

Hey guys went to use the cup holder and found out the inside arm on my drivers side is bust ! Are any of you aware of anyone making or 3d printing these ? Be amazing if you are and i would be keen or if you have plans etc I might be able to get guy at work to do it... thoughts ?

[Jfgoldfish]

Cheers mate that would be great I appreciate that.

So, I have one left from the last batch I printed.
I can send it over to you if you like.

Or if you would prefer to wait for me to print more (both sides), I will send this one to Robbo. I think it is a drivers side.

[Jfgoldfish]

Be amazing if you are and i would be keen or if you have plans

There is a good design available on thingiverse if you do decide to get a work colleague to print for you.
They should really be printed in ABS so make sure your chap is capable of doing that . I cant see PLA lasting too long.

Otherwise, I will be getting some more black ABS soon. It looks like theses are in popular demand so I should print some more!
I am currently able to print:
cup holder arms
wheel arch (headlight) cover clips
transmission tunnel screw covers
behind seat storage compartment repair clips

I will let you know when my filament arrives.