I printed out the Patent Drawing in a couple different sizes and made a few card stock mockups. The photos show three different sizes. The largest one is just under 5" wide. I am still tweaking the pattern and I think Matt said his was 5-1/2" wide. I need to find out how he measured the cup he has.
I am holding the cups together with #8-32 Nylon screws and nuts. Finding Rivets and what ever it takes to make them work may not be worth the cost just for one or two cups. For my own cup(s) I might just use try one with the Nylon screws and nuts. I can cut off the extra from the end of the screws and then heat the tip to melt a cap of sorts on that end. I might make one using the Nylon screws and nuts just to see how long it lasts.
The "for real" cup could be made from one of several different material I have on hand. I have .016" titanium, .018" Stainless Steel, 1/32" aluminum and a thin plastic. I will decide later tonight which I will try first but I might go with the aluminum till I decide if I need to change my pattern.
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