I want to make a simple tv tray that has a plug the same size as the cupholder on my Berklines. The size needs to be almost exactly 3 1/4" diam and 2" tall. They need to fit snug to not fall out easily. I don't expect super-strength, just somewhere to put a plate of food.

Using the cupholder gives a round mounting point that swivels. The cupholder is also level, and firmly in place in the chair.

The best would be a solid cylinder the exact diameter that I could screw a tray onto from the top, but I'm having trouble thinking what comes in that size. I can shave 3" ID pvc pipe down to fit, but its a hassle, and its still hollow, so I would need a flat plug to fill the top to give a surface to bolt the tray to.

I thought of using the cupholder as a mold for fiberglass resin, but dont know enough about using it to know how brittle, expensive, hard to work with, etc. it would be.

Is there another material than resin that would work?

I even thought if I needed the extra resistance from cupholder movement, I could mold in a 1" long 16 peny nail, cut to length, and drill a small hole at the bottom of the cupholder into the wood brace beneath the holder. You would never notice the hole unless you knew where to look, and the nail would add great support.

If I knew someone who had a wood lathe, I could make the exact size cylinder from a 4x4.

This would be easy to do once I had the proper material for the plug figured out. It would be easy to store since it wouldn't have legs.

Berkline has a model with a tray option, but they drill and mount another tube in front of the cupholder for a thinner rod that sticks down from their tray, but that would mean cutting a new hole thru the leather, and bracing it from below (the wood under the cupholder doesn't go far enough forward to also support this in my chair).

This can't be that hard, and it would be easy for any of us to do once we get enough people with the various bits of knowledge about materials to suggest something I can use to make a sturdy, machinable (at least to drill thru or screw into) 3 1/4" plug.

Any ideas?

The size needs to be almost exactly 3 1/4" diam and 2" tall.

That part is easy, if you know where to look.

www.mcmaster.com --> raw materials --> plastics --> rods and discs --> 3-1/4" diameter --> cut-to-length.

7 materials to choose from, white polyethylene and gray PVC are the cheapest. I was able to put in 0.15 ft (1.8in) as the cut length, for a cost of around $3 plus shipping.

Thanks a lot!

Wow - sounds like a fun project - I just ordered some cut rods!

Randy

http://www.theaterseatstore.com/cinema-snack-tray?sc=14&category=208

I don't know if others have had the same problems or not, but not all of my cup holders in my Berkline 13175's are the exact same diameter.

CJ

That part is easy, if you know where to look.

www.mcmaster.com --> raw materials --> plastics --> rods and discs --> 3-1/4" diameter --> cut-to-length.

7 materials to choose from, white polyethylene and gray PVC are the cheapest. I was able to put in 0.15 ft (1.8in) as the cut length, for a cost of around $3 plus shipping.

Ack - ordered and they shipped FAST, but when I opened the box today, I found that I got a single rod, 1 foot tall, not cut to size as I requested. They claimed they couldn't cut as I'd ordered.

So, now I have to figure out how to get it cut. It's the right diameter, just, er, tall.

http://farm3.static.flickr.com/2786/4029089659_d97fae49aa_m.jpg
http://farm3.static.flickr.com/2463/4029844224_40a1e01eac_m.jpg

I've started a project page, here: http://www.cinemamurray.com/Cinema_Murray_Online/Seat_Tray_Project.html

Ack - ordered and they shipped FAST

Yeah, to central MD their deliveries often end up being next-day even with the most basic shipping.

but when I opened the box today, I found that I got a single rod, 1 foot tall, not cut to size as I requested.

Whoops. I assumed the fact that it allowed a fractional cut length meant that they could actually do it.

Is the plastic soft, like PVC, or is it brick hard?
A hack saw with sandpaper cleanup may work if it's soft.
Will the plastic take a drill and tap on the end? Or maybe it will take PVC type glue/solvent to bond to a plexiglass or similar type tray

Not soft at all - pretty dense stuff!

But I do think I'll be able to drill it - and PVC glue or others should work to bond it to a tray - still not sure what I'll end up using for the tray surface.

Randy

Jeff - check your pm.

tum

bump.
Any updates on this project?
Though maybe I could use some mods to incorporate the dancing snack trays.
To put my snack and Bubba Keg on of course! ;)