[DIY / 3D Print] FL5 Custom Covered Storage Box (WIP)

[aqf23]

Hey everyone,

After the great feedback on my previous project—the FL5 Precision Fender Vent Guards—I'm back with another CAD and 3D printing project for the FL5!

To be completely honest, I thought about starting this project over half a year ago, but life got busy. On top of that, I’ll admit I felt a bit demotivated after seeing my fender guard designs being ripped off and sold elsewhere without my permission. It definitely takes the wind out of your sails when you design something for the community non-profit, only for others to monetize it. It’s also crazy to me that years after the FL5 was released, there still isn’t a proper commercial aftermarket solution for this area! But here we are—I still want a proper fix for my own car.

Personally, I think the open dual cupholder is the most useless feature in the entire FL5 interior. It’s a huge open "pit" right in the center console that breaks the clean cockpit aesthetic, when it should be one of the most practical storage spots in the car.

My goal for this project is to convert that open space into a proper, covered OEM+ style storage compartment.

The Concept & Features:

• Mercedes-Style Butterfly Lids: Instead of a single massive door, it will feature two lids opening split down the middle toward the sides.
• Removable Internal Tray: Inside the main compartment, there will be a removable drop-in tray to keep small daily items organized.
• Push-Button Spring Mechanism: A button release will trigger two springs to snap/flip both doors open outward to each side.
• 100% Reversible / Press-Fit Mounting: The entire base assembly (FL5_Cupholder_Frame_Base) will be a friction press-fit into the factory cupholder recess. I'll be using a 2mm high-density foam tape layer on the contact surfaces—this guarantees a snug fit, prevents any potential rattles/vibrations, and protects the factory OEM plastics from getting scratched or marked. No permanent modifications, drilling, or screws required.

Current CAD Challenges & Design State:
The design is still very much a work-in-progress and a bit "up in the air."

Looking closely at the 3D scan data, I realized the main hurdle isn't just the clearance around the shifter trim, but the downward sloping angle of the center console toward the armrest.

This compound angle makes designing a single-piece butterfly lid assembly really tricky. If I design the lids flat or at a single fixed plane, I end up sacrificing a massive amount of usable internal volume—especially at the very back right in front of the armrest storage. Finding the balance between maximum storage volume, proper door sweep clearance, and a sleek top profile is taking some back-and-forth in CAD.

I’m currently tweaking the hinge alignment and lid geometry off the 3D scan to recover as much depth as possible.

I’ll be updating this thread as I iterate through test prints and refine the mechanism. I'd love to hear your thoughts or feedback!

Cheers!

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