Cup Holder for Xterra TR150 Treadmill

This will clamp onto anything that is about 31.5mm X 56mm, at a 14 degree angle, and has totally rounded edges (like the arm of the TR150 treadmill). It is made to attach to the right (starboard) side of the treadmill from the perspective of someone standing on it and facing the right way. To attach it to the left side you would need to make a mirror image of the sagittal brace and the clamp (because of the direction of the peg holes).

Tools/supplies needed:

1x M6x35mm bold w/ nut and washer

Epoxy

Hammer and solid surface to hammer on

Pliers

Optional:

Drill/dremel w/ 5/32" bit

Sandpaper/file

Instructions:

After printing the parts in the orientation shown in the .3MF file, first attach the clamp to the sagittal brace. If you have a drill, use the 5/32" bit to drill out the peg holes in the sagittal brace and clamp. This makes it a bit easier to get the pegs in, but is not necessary. You can also use a file or sandpaper to lightly chamfer the end of the pegs so they go in easier, but this also should not be necessary. Next attempt to assemble the clamp without epoxy and without putting the pegs all the way in, just to make sure that everything fits together and the peg holes line up. Use the pliers to pull the pegs back out of the peg holes. Next, apply epoxy to the groove on the brace that the clamp fits into, then put the clamp in, and then lay the assembly on its side. Now apply a small amount of epoxy to the end of a peg, and gently hammer the peg into the peg hole. You may have to shift the clamp back and forth to get the holes to align. Do the same with the second peg.

Now, apply some epoxy to the groove on one side of the sagittal brace, keeping the epoxy mostly on the outer side of the groove (so it doesn't get pushed into the inside of the cup holder as much). Don't apply too much as it will mostly get pushed out of place anyways when the gunwhale slides down into the groove. Now slide one of the gunwhales (it doesn't matter which one) down into the groove and make sure it goes all the way to the bottom. Do the same for the other one.

About the epoxy-- you can either wipe the excess off with a damp paper towel while it is wet or wait until it cures and pull it or cut it off. For the external areas I think it is best to pull or cut it off after it cures as this leaves a uniform finish. For the internal part, it is hard to do this so it may be better to wipe it off before it dries even though that leaves a bit of smeared epoxy on the finished part.

Note on naming convention:

I like to use analogous nautical terms for naming my parts when possible, but in this case it is quite a stretch to call the sides of a cupholder gunwhales. Really they're more like the hull than just the gunwhale but that was the term that came to me when I started this project and it stuck. I apologize for any eye-rolling this may have caused.