Audi Dash Cupholder Repair Bracers

thingiverse

Note: I've been told that some of my models don't print out at the right size on certain programs. The correct length for these is 2 inches. If it's not 2 inches in your software, please scale the whole object to meet that length. This is a simple set of bracers designed specifically for the flimsy fold-out cup holders found in older model Audis. These are only useful for cup holders with cracked plastic where the back of the cup holder armature connects into the socket, causing the entire cup holder to bend downward when a heavy drink is placed in it. This video does a better job explaining how to remove and disassemble the cup holder than I can with words: https://www.youtube.com/watch?v=qPfmNJk1UXk. He's solving a different problem, but the disassembly and reassembly are still useful. Credit goes to its creator; I'm not responsible for the video. Once the cupholder assembly is removed from the sleeve, you'll see where the cracks in the armature are (I've included photos above). These bracers are intended to be glued down over the cracked area and distribute the load to the rear of the assembly. Use Gorilla glue and clamps to ensure a strong bond and flush surfaces. If you get glue in the small cutout area where there's a pivot hole, make sure you clear it out or you risk inhibiting the unfolding action of the cupholder (can be cleared with a knife after the glue is dry; Gorilla glue can just be picked off). Once clamped for at least 12 hours and left to rest another 12 hours, reassemble the unit and put it back in your car. If you print in black, you won't even notice they're there. The bracers as a pair are rated for 4lbs, which is equivalent to 64oz of water. After installing them on my dash cup holder, I've successfully held a 32oz drink without any flex. The two rear cup holders and the in-dash cup holder all have the same design and can use this bracer. I'm not sure what models or years were the same, but I based the models on my 2001 A6. Printer settings: * Printer: Da Vinci Pro * Rafts: No * Supports: No * Resolution: 0.1mm * Infill: N/A Notes: Due to the thickness of the part and the stress applied to it, I recommend printing with as small a layer height as possible and as high an infill as you can manage. I printed the top and bottom layers so thick that there was no infill. I also recommend only printing from ABS. Stress analysis was done with properties for ABS, and I'm not sure if PLA will hold up without flexing or even breaking. When pulling this off the bed, it'll feel flimsy. It's very delicate when bent across the thin area perpendicularly to the part. It's designed with strength in the parallel direction because all the force will be placed on it in that direction, and once glued down, it should experience zero force perpendicular to the surface.