Messing around with 3D printing
Reply #56 –
I got the remaining pieces in today. Overall, the fit is pretty good, and everything works. I made a couple of minor tweaks to the models on Shapeways to make it all a little easier:
1. Made the screw mounts on the bezel a little smaller to make it compatible with existing cupholder sleeves (and made the corresponding holes in the sleeve smaller).
2. Enlarged the screw hole at the back of the sleeve (for mounting the pin holder) to make it easier to put a screw in.
3. Added a little tab to retain the spring on its holding pin to keep it from coming off (for the existing model, just use a spring that is a little tight or add a drop of glue to hold it on).
4. Moved the pin holes on the tray down 0.5mm to try to make it compatible with existing arm pieces.
5. Widened the wedge-shaped guide at the top of the sleeve by 2mm for a better fit with the small guide pins at the top of the tray.
6. Pulled the retention hooks on the inner guide pieces in by 0.5mm for a tighter fit.
7. Rounded two edges on the bezel mounting points to make it compatible with existing sleeves.
One thing I noticed is that since the spring is off-center, it causes the tray to turn just a little, as seen here with the bezel. I'm not sure yet what to do here, but a washer on one the bezel's mounting pins should correct it, I think.
Edit: Change #6 might straighten out the tray when it's under tension.
Edit: Here is a pic with an existing sleeve. I scrounged up a couple of aluminum PC screws and trimmed the bezel with a Swiss Army knife for changes #1 and #7 above, and put it all together. I'm very happy with the fit; it's nearly perfect.