Custom Mini Center Console W/Cup Holders & Even a Fan!

[KIRK!]

I like minimalism. I wanted cup holders, but I don't want to look at them all time or need a center console with a bunch of pretty useless compartments. I tried to get into having one of those basket cup holder things, but I didn't like the look nor the limited functionality, so I decided to build my own with just the couple of things I wanted in its design - removable cup holders and ice cold AC.

I scoured the Interwebs to find removable or easily hidden cup holders and settled on these that came in 2016-21 Mazda Miatas. They are cup holders you can throw in the glove box and so they're not in your way and you don't have to look at them, but don’t look like cheap clip on holders when in use. I decided to order a setup and make it work for my Squareback.

This is what it looks like with the cup holders installed in the Mazda base. They just pop in and out through the little trap doors but stay very sturdy when in place.

The cup holder bits and their part numbers.

The base part. Obviously it goes under the center console panel in the Mazda. Part number is molded into the bottom for anyone interested.

I don't need the stock mounting points, so I removed the door/lid to keep it safe while I cut off all the fat.

Now that I had just the bit I needed I knew what the minimum inside width of my mini console would be. Then I scored a vintage 12V fan and found the minimum distance it could be from the cup holders and have the speed knob/switch still fairly accessible. I didn't want it to just be a square block sitting in front of the shifter so I added rounded ends to hopefully make it feel more "finished".

Cue the sketch paper and Adobe Illustrator montage...

What? There isn't one? OK, working with my minimum dimensions I sketched it out and then created the cut patterns in Illustrator. The files were sent to the awesome people at SendCutSend.com. I use them for cutting stuff for fabrication these days because they have great, fast service and very reasonably priced. Plus I’m lazy. I chose WAY heavier material than needed for such a non-stress part, but oh well.

After a few minutes on the brake it started to take shape. I also tapped the side holes in the base that will hold on the cover. I was relieved to find that my measurements seemed like they were going to work, but I really won't know until the welding is finished.

Cue the weld-bend-weld-bend-weld montage...

For fuck sakes! You'll have to use your imagination, but you get the idea. Bend the end tab down, tack weld, and repeat. I went back in and finished the welds. The top slid right onto the base AND the holes in the cover lined up perfectly with the threaded ones in the base.

If you look close the insert has a small lip around the doors. Test fitting the lip and the opening was a success. I was super close on the interior height I needed to keep the cup holder insert securely in the opening for it. I needed something pretty thin and with some give so that I don't crack it if the fit ends up too tight. VELCRO! Not generic hook'n'loop, but real, genuine pure self stick Velcro.

I just held the insert in place from the top as I put the cover on so it would end up exactly where it needed to be in the base and the Velcro provided enough height and cushion to hold the insert up against the lid while the lip is secured within the opening. Here's what it will look like assembled. Can't wait to have to always wear long underwear with that AC pumping that ice cold air from the front footwell.

My part is done. My friend's 20-year-old daughter is opening her own upholstery business and is literally in the middle of her first paying full upholstery job on a Model A roadster. Happy to be her second paying gig. I'm using a leather shift boot and I've asked her to stitch up a leather cover for this to match. I can't wait to see how she does.

I'll update as soon as she's done...

[Max Welton]

I love this!

Max
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1967 Type-3 Fastback
Under the Knife https://shoptalkforums.com/viewtopic.php?f=24&t=151582
Home Stretch https://www.thesamba.com/vw/forum/viewtopic.php?t=767836

[bigwhit]

This went from "WTH?!?" to "Noice!" very quickly.
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[Lou-Lou]

Wow...

[Bobnotch]

That turned out really nice. But it looks too small for my travel cup.
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[Max Welton]

The vintage fan is a nice touch.

Max
_________________
1967 Type-3 Fastback
Under the Knife https://shoptalkforums.com/viewtopic.php?f=24&t=151582
Home Stretch https://www.thesamba.com/vw/forum/viewtopic.php?t=767836

[KIRK!]

[KIRK!]

[KIRK!]

[KIRK!]

Back from the 20-year-old future upholstery wiz! I think she did a great job! Looks good next to the leather shift boot. Now to finalize the mounting for the console and the shift boot. Oh, and I have a leather e-brake cover.

Can't wait to get the carpet in and see it finished!

[bigwhit]

Cheese & Rice
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"All Glory Comes From Daring To Begin" William Shakespeare

[Scotty D]

Excellent design. Well done.

The leather wrap looks amazing as well.

Looking forward to pics of the finished interior.

[KIRK!]

I just remembered that I need to be able to adapt the console to the curve of the tunnel. I’m about 3 weeks new to 3D printing and this is the first part I designed myself and printed. Pretty happy with the result and it hugs the tunnel perfectly. Ignore the dumb texture. I was experimenting. This will screw to the tunnel, then carpet, then the mini console screws to this through the carpet. Getting the two lined up through the carpet will be a challenge to be sure.

If I had known parts like this were going to be doable about a month earlier. I would have made the metal housing 3D printed instead. I could have made this the base and have it sit on top of the carpet and then have the sides of the top extend down to meet the carpet. Next time around I guess.

Tell me why not to screw into the tunnel, forward of the shifter.

[Max Welton]

Brilliant.

Max
_________________
1967 Type-3 Fastback
Under the Knife https://shoptalkforums.com/viewtopic.php?f=24&t=151582
Home Stretch https://www.thesamba.com/vw/forum/viewtopic.php?t=767836

[EverettB]

Looks good.

The only thing that struck me was the length of those screws.

I don't think anything is up there on the tunnel so my only thought was if you ever have to remove the shift rod to do the shift bushing, screws that long could be in the way. This isn't something that you would be doing very often, if at all, so of course you could unscrew the bracket first.
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[KIRK!]

The ones I’m going to use are shorter. This is just the one that was on the workbench.

[Mike Fisher]

I'd buy one if you put them in production?

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[KIRK!]

I wish. The components are way too expensive. Just the cup holder parts are almost $300. It's dumb.