Porsche 911 / Boxster Cup Holder Disassembly + Reassembly DIY Tutorial
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- Опубліковано 25 сер 2024
- Learn to take apart, and put back together, the most complicated cup holder ever put into an automobile! This is a feat of engineering, but over time the little plastic parts become brittle and break. Up until now, you just had to replace the entire assembly ($300!). I walk you through step by step how to take everything apart and then put it all back together so that you can replace the broken pieces.
I've been testing the parts in my car for a while and am now completely confident in their durability. If you'd like to purchase them please contact me. My email address is my username on UA-cam at gmail.
If you just need the T-8 bit, you can get this set: amzn.to/2NkqhGn
If you need a driver as well here is one: amzn.to/2JvJRNJ
People, this is amazing. Contact Charlie and buy the repair kit from him. Then be prepared to spend a 2-3 hours to do this. Good lighting and proper tools are essential. Charlie mentions having "infinite patience". I don't have that but am very persistent and completed the repair. I couldn't be happier. 10 German engineers stayed up all night for a couple of days designing that thing... absurb but really very cool too. I was intimidated by the idea of getting the cup holder cartridge out but it's really quite easy. Use a plastic plying device (I used the tool used to get a bike tire off the rim to change the tube). Start at the bottom on each side of "horse shoe" and pop it loose. It sounds and feels like you're breaking it but that's normal. Then do the 2 top corners. It's then pretty easy to disconnect all the switches. Definitely take pictures for insurance on getting it back together correctly. I should've made a video but this step-by-step info should suffice. You then need to remove the air vent thing. There are 2 silver clips on the top. Reach in with a small screwdriver, depress them, and the vent piece pops out easily. At that point, you have to remove the 4 screws that hold the frame in place. The frame then only needs to come out and down a bit, maybe 3-4 inches. At this point, the silver clips on the top of the cup holder cartridge are easy to press down and the troublesome cup holder can easily be slid out the back (ie, towards the front of the car). Repeat in reverse after you completed Charlie's video. I had to do it twice as I lined up the face plate 1 cog to the right. When I had it all back together, it rubbed and wouldn't open/close properly. I had to redo the whole process! The edges of the face plate need to line up symmetrically with the corresponding edges of the cartridge. The critical part is when the faceplate is slid into place. Pay attention to Charlie on that part and don't shift the allignment of the plate and the part it slides into as you're uniting them. You'll know what I mean when you get there. I also had trouble reloading the tension spring but was ultimately able to get it. It is under a lot of tension and needs to sit on top of one of Charlie's new "arms" and below the housing. Getting that right while wrestling the spring into place is tricky. My fingers are still sore today. Patience is critical and persistence is helpful too. Good luck to all.
Awesome - glad you were able to get it fixed, nice work!
@@charlieaf92 Hello how can i onnect you i ned 2 gears :-)) greets
@@Mario-ik2em email me charlieaf92@gmail
Just finished mine and works again like a charm. The gear as well as the small hook to move same were broken as described in the video and now replaced with new 3D printed parts.
Would like to thank Charlie for the assistance and for taking the time to sort this out as well as for making this great video with full instructions.
What are the symptoms of this being broken. I think I have an issue but. Not sure what. It doesn't open on pressing, I have to apply some pressure in the. Idle and do it just right for it to spring out. Almost as though something is jamming it when shut.
Wanted to thank you for this easy to follow video tutorial. After ordering a set of quality replacement parts from you, I was able to fully repair this complicated engineering marvel known simply as a cup holder. Much appreciated, Charlie!!!
Awesome! My pleasure. So glad you got it sorted out.
video just saved me $300. second time you've saved me a lot of money after rebuilding the cv joints. I tried to do it first without watching the video and that was a mistake. great stuff. thanks very much.
Awesome! I'm so happy to hear that. Thanks for letting me know.
You are a legend and I now have a fully functioning cup holder. Many thanks, would have been a frustrating rebuild without your tutorial. 👍🏻
Awesome! Thanks so much for the kind words. I'm thrilled that this video helped you out!
That dang cup holder is way too complicated. It is ridiculous. Props for going through the complete repair.
Agreed - it's beyond silly. I'm glad I finally bit the bullet and fixed it though. Once you do it, it becomes much less intimidating.
Great video and great job recreating the parts. I received mine the other day and followed the video. Works perfectly again!!
My cupholder isn't working so I'm going to have to pull it out and watch this video!! Very helpful videos you do. Thanks so much.
Happy to hear it will help you out. Feel free to post any questions along the way in the comments!
Great job on the video, thank you for posting. I offer replacement faceplates and the gear as well....not 3D printed though. You put a lot of work into this video, good job!
Mine will not latch back into place in the dash. Will be taking apart this weekend. Great video!
Excellent video. My 2003 996 cup holder is stuck in closed position. It will open on about the 10th+ attempt how ever.
When open every thing seems solid and functional, spring tension seems ok. Might it be a broken part inside? Maybe some sort of adjustment? Trying to avoid removing unit if possible. A German watch maker must have invented this gadget! lol
Reminds me of a "Rube Goldberg machine" : ) TIA from NC
I have the same issue. Did you fix yours?
@@docloco86 I have not made time to fix the 996 cup holder, as I am not certain how to proceed, yet.
I bought a 997 turbo w low miles (before prices went up) and thankfully every thing works on the 997.
I want to sell the 996 (IMS replaced) so I need to study the stuck cup holder carefully, with out making the matter worse.
I will try to keep you posted. If you find any info on how to pic this lock, please let me know. Brian
Thanks for this video. I couldn't have fixed my cup holder without it. I had to buy a salvaged unit and then combined working parts from mine and the salvaged unit to make one working unit. Very nice now. Much more work than I thought it would be though.
Glad it helped! Thanks for letting me know.
Charlie, amazing. I have the broken gear plus a broken actuator for the gear. Are you selling a kit that included the gear and actuator?
Truly excellent work, thank you for sharing!
Great DIY. Thanks for posting!
Thank you for this! Gotta love German engineering!
Are you printing in ABS or PETG? I'm assuming that PLA wouldn't be able to take the heat inside a car in the summer.
You're welcome! I printed in PETG for that reason - I don't think PLA would withstand the heat. I've had my replacement parts installed for 6 months now and they're working perfectly.
Wow, you do have patience. My cup holder has just broken so this video is very helpful. Thank you for putting this together. I am not impressed with the complexity of the German mechanism at all. Genius in my opinion is simplicity. Maybe that's why I like my Toyota so much better. Anyone can make something complex, no brains there.
Good video - very helpful. Could you do another one on how to remove the cup holder mechanism from the dash? There doesn't seem to be much information about that anywhere. And I would be interested in a repair kit.
Unfortunately I can't do one with removal, there is a decent video here that discusses removing the horseshoe surround ua-cam.com/video/6oSrNBXlH_o/v-deo.html&ab_channel=HeidiandFranny%27sGarage . Once you have that off you need to remove the center vent, radio, AC controls, ect so that you can remove the bracket that the cup holder is mounted in. Once the bracket is out of the car, the cup holder slides out the back side of it. Best of luck with your project. If you are interested in the parts kit, send me an email at charlieaf92 at gmail. Cheers.
I've just fixed the same damn gear but found the broken piece and glued it back so fully operational thanks to you. Where can I get your uprated ⚙️?
Nice! You can email me about the gear. Just send it to my youtube username @gmail
@@charlieaf92 emailed you. Are you able to share the 3d schematics for printing myself? I'm based in London so might be easier this way. :)
Mine does not close anymore and a small part from the faceplate is broken too. I would love to get it working again. Can you help me with your parts ?
Question: Do you happen to have the link for cupholder removal from the dash? I found one result on YT but declipping the top pins that would normally sit just below the vents doesnt seem to want to release the cupholder cartridge. Thanks in advance and thannks for making this video!
I don't, unfortunately. It's been years since I've done it but you have to remove the vents, and the horseshoe. The cupholder itself has to be pushed out the BACK of the bracket that it is mounted in. So, in order to remove it you have to take the entire bracket out - which involves unhooking the radio/HVAC controls/etc. Hope this helps.
Hi Charlie, I'm about to pull my cup holder out and give it some TLC. The gear that drives that front plate - mine must be broken since that function doesn't work. Do yo supply the part or can you provide me with the 3D print file for the part as I have my own printer. Great video and thanks for taking the time to put this together. Could be a ruined weekend of lost springs otherwise!
Hi Charlie
Great video! I couldn’t find the video where you’d take the cup holders unit off the car. Could you please share the link? I’ve got the horseshoe and AC vents off but can’t seem to get the cup holders off even after pressing down on the two pins and pulling the cup holders out.. seems to be stuck somehow still…
Hey Tommy! Unfortunately I never made the video. I just didn't have the time (or patience to redo it all to film). Anyway, the design is a bit strange - the cup holder needs to slide out from the BACK of the metal bracket it is in. So, in order to actually remove it you have to take the bracket out of the car. Then there are a couple tabs to press down and the cup holder slides out. Hope this helps!
Hi - thanks so much for this wonderful video- i can’t find the link for the driver gear for 3D printer ie the stl file?- is that something that you are willing to share also?
Thanks in advance, can you also share the link for removal from dash- I don’t want to muck it up!!!
RM
Very good video !
Do you have a video showing how to remove the cup holder from the dash ?
Hey Arthur - thanks! Unfortunately I don't have a video of how to remove it from the dash. I tried to make one, but since I'd never done it before it turned into a jumbled mess. You need to remove the horseshoe from around the radio, then remove the center vent, then the entire frame that holds the cup holder and the radio needs to come out. There is a good video from Heidi and Franny that show's how to remove the horseshoe: ua-cam.com/video/6oSrNBXlH_o/v-deo.html
@@charlieaf92 thanks
Do you share the stl file for the faceplate pinion gear?
Hey Clint. Send me an email (my youtube username @ gmail) and we can dicsuss.
Hi. Did you get the model of the opinion gear? Is it shareable?
Hey Charlie I have a 996 c4 2002 model and in my try to put a face plate on the cup holder seems that the small plastic part with the Crown that fits on the gear is broken and now the cup holder is not closing and stays open. What can I do?
I don’t know maybe it’s irrelevant because in the video that part only moving the cover. So it must be something else that prevents from closing
Great Video! My question is will the 2 drawer cup holder sold by ECS-Tuning E-store replace this unit in the 2003 Porsche Boxster S?
Hey Gary - I don't think it is a direct replacement. I can't say for sure though.
Where can I source some of the small intricate pieces? I do not own a 3D printer. Great vid; thanks for taking the time to do it
Hey Bill - I sell them as a kit. Email me for details ( charlieaf92 @ Gmail )
Hello, my cup holder won’t stay in. Can you please tell where I can contact you for a replacement part? Thanks! 🙏
Sure thing, you can email me at charlieaf92 at gmail. Unfortunately if it isn't staying closed, my part kit might not help you. But we can discuss.
Great video! Sent you an email, would like more info on your replacement parts. Thanks!
Hi Charleaf, My 986 cupholder just failed (will not stay closed) and I would like to order your kit/parts please. Incredible video, man!
Hey Gary - thanks! Send me an email charlieaf92 at gmail dot com and I'll get you the details on the kit.
charlieaf92 Hope your still around on youtube I think I have a broken gear as you described in the video. I also have a 03 Boxster and the problem is I can't even get the stupid thing out of the dash. I have taken all the trim off and the temp control assembly but cant see any screws or tabs that will release the whole cup holder assy. After looking at your vid I see 2 tabs on each end of the assy. I'll try that if not I hope you can answer this comment. I lloked up the unit on Pelican parts and they want $400 for a new one, thats crazy even for Porsche.
Hey ksheeh - The entire cup holder assembly actually pushes out through the back. So in order to remove it, you need to remove the "frame" that it is in and get it out of the car. Once out of the car you should be able to get it out. Feel free to email me some pictures of where you're at and I can try to provide some pointers. It's been a few years since I've done it so seeing it will help jog my memory. Cheers.
Charlie... I'd like to buy the rebuild kit you mention. How do I get you money and get the parts from you?
Great video, I have mine apart to glue the same parts you made back together, will you be selling a repair kit soon?
Yes I have sold a few of them so far. If you'd like more information please email me. My email address is my youtube username @gmail.com
Cup holders above electronics should never be used. The one in my 996TT works but don't want to use it as it sits above a pccm+ system
Charlie: how can I reach you? I’d like to have you make a cog for me but, don’t know how to contact you directly.
I purchased a new assembly just to replace the faceplate (i'm an idiot). How does one remove just the faceplate? Hopefully I don't have to disassembly the entire device. Thanks.
You're not an idiot! You have a bunch of spare parts now! To be honest, I'm not sure if you can remove the faceplate without disassembling the entire thing. I'd be worried about potentially breaking it. Hopefully someone else may have tried this and can give you a definitive answer. IF it is possible I believe it would be done by putting the cup holder in the open position and then sliding the faceplate to the right. There are little tabs on the back of it that go in a slot. The slot opens up at the extreme right position and allows the faceplate to pull off. Good luck, but go slow and be careful.
@@charlieaf92 Great, thanks for the info. I guess I can disassemble the new one to get it off. The only trick then is to assembly it to the car without breaking anything.....
@@charlieaf92 Just so you know...... I removed the new faceplate pretty much like you said. Open the cupholder so the faceplate moves to the right. I used a plastic prybar to move it farther to the right. Click!! Went to the car, put in place and pushed it to the left. Click! Thanks again
@@davidrinaldis2351 Excellent, thank you for sharing!
Charlie, I am interested in picking up one of these gears from you. Can you duplicate the gear for purchase?
Hey Christopher. Yup, I've been selling little parts kits. Email me for details: charlieaf92 at gmail
charlieaf92 Thank you sir, email has been sent.
I'd like to know about a repair kit. I emailed but have not heard back. Can you please send me some information?
Hey David - I either missed your email or it didn't come through. Could you please send me another one? charlieaf92 at gmail.
Sent an email!
Do you happen to have the part numbers or produce the faceplate or this arm (I believe it's the locking arm) but it's pictured here imgur.com/gallery/kp3W62i as the cupholders wouldn't stay in the closed position at all in the car
Other than that great video, I'm a career tech and this helped me, I wasn't trying to pay friggin 380 for a new one for my 996tt
As far as I know, they don't sell individual parts and only the entire unit. The faceplate is a common point of failure, so most used/parts units you see on eBay don't include it. Unfortunately I've never gotten around to modeling and producing replacement faceplates. However I have successfully reproduced the arm that broke. Feel free to email me charlieaf92 at gmail.
Hi, not sure you are still monitoring this thread, but I sent you an email. Nice video and I am interested in the kit to repair mine.
Hi there. I sent you an email to your Gmail re: 3d models. Cheers.