How to Repair my Cup Holder

Click on the pictures to see a larger view

 

Here's a challenge...

 

My cup holder is broken; well actually the pop out function is not working. or to be more precise the mechanism that holds the cup holder inside the dash is not working and so it keeps popping out.

Below is a series of pictures outlining what the problem is and I am hoping you guys can help me fix it.

It looks like a very delicate job to fix it but I am sure there is enough expertise in this forum that can help me resolve it.

 

When the holder is out of the dash it looks like this...

What amazes me is that someone sat down and designed this mechanism which on the face of it looks a bit OTT when you consider it is only a cup holder.

That part that operates the open and close mechanism is illustrated by the red arrow here...

This when working properly makes a hook type lever to move up and down

  

Up

Down

  

The reverse side of the mechanism looks like this

 

Where the red arrows are a very small lug fits in there and moves back and forth like a key and eventually hooking in behind what looks like an inverted letter "C".  On pressing the front of the cup holder in the dash this causes the lug to disengage from the inverted "C" allowing the cup holder to spring out of the compartment. The grips then open allowing the driver to pop his cup into the holder. (Unless it is arseless - nudge nudge Flyer  <Grin>)

 

Now lets take a look at where the lug is supposed to be...

On the part of the holder that pops out is a section that is prone to break...

Close up of it...

 

The lug is supposed to be on here...

Close up again...

The lug is missing from here...

What I have to do is make another lug and fit it in place.  It has to be strong enough to hold the cup holder in place by hooking in behind the inverted "C" on the main part of the mechanism.

To give you an idea of the sizes we are dealing with The large metal bar in this picture is the end of a small paperclip.

So the lug has to be very small; I am guessing about 1 millimetre thick by about 3 - 4 millimetres long

 

What  I need to know is how do I make one? and How do I get it to stick the the body where it belongs? and Be strong enough to hold the cup holder in when not in use?

 

This is the interesting bit...

Now here is a challenge to you all if your up to it...

 

I have figures out a very simple way of fixing this without any manufacturing or gluing or any fiddling whatsoever.

 

I challenge you guys to work this out...  All the clues are in the pictures.

 

Are you up for it!!!  Can you figure out how to make it work it in the simple way without tossing it out and buying another???

 

 

 

Oh and BTW  It is not an arseless cup holder, here's proof...

  

 

 

All answers on the back of a postcard and posted to Flyer for his wedding.

 

 

To take out the rear cupholder the seat has to be lifted up.

     

 

        

        

Edd