mike27t

I used the <a href="https://www.audiworld.com/tech/elec85.shtml">Retrofitting an Auxiliary Cigarette Lighter</a> article as a guide to adding one to my 2003 A6. I did some things differently which may be of interest.

I went to my local VW dealer to get the parts mentioned but found that the socket part (Part#: 1J0-919-309) was $9.42 and was not enclosed and didn't have any kind of mounting that could be used. The cap (Part#: 1J0-919-341-F) was $9.72 and not in stock. Looking at different parts pictures for VWs, none seemed to be right. So instead I went to my local Pepboys and picked by a covered auxillary power socket by <a href="http://www.bellautomotive.com/asp/product_details.asp?id=23217">Bell (Part #39048-4)</a> for $6.99 as shown in the picture below and link.
<img src="http://pictureposter.audiworld.com/53905/aux_socket1.jpg">
I discarded the wires (too short), the wire taps (see below why), and the mounting plate and screw. The only thing people might object to is that the cover is thin soft plastic rather than hard plastic with a OEM look.

In order to fit the socket to the plastic piece below the armrest I made a paper template for the cutout as shown in the pictures below.
<img src="http://pictureposter.audiworld.com/53905/aux_socket2.jpg">
<img src="https://www.audiworld.com/tech/pics/elec85-cig4.jpg">

This aux socket requires a 3/4" hole which I made with a smaller drill bit and then widened with a dremel. Be careful to use the lowest speed as the heat from higher speeds melts the plastic and the dremel sander goes through the plastic like a knife through butter.

In order to stop the socket from lifting I placed a washer between the screw fitting and the bottom of the plastic tray beneath the arm rest. Notice how the screw ground fitting for the socket wraps over the socker portion. Because of the thickness of the two pieces of plastic and the washer, I had to cut about 1/2" off the screw fitting so that it would still fit and tighten correctly. A hacksaw or dremel will do the job quite nicely

I then lifted the trim piece as stated in the original article and screwed everything into place. My socket is tight and is not going anywhere.

When I investigated wiring the aux socket into the cigarette lighter in the rear passenger area, I decided I wanted to stay stock and not use wire taps. Note also that I did not have to remove the 4" piece of angled HVAC vent as stated in the original article.

After threading wires from the socket to the rear, I crimped on some spades and pushed the spades into the original connector as shown in the picture below. This works pretty well and it doesn't really matter to me that the rear cigaratte lighter no longer has power. In fact I used one of those "no smoking" socket covers in its place instead.
<img src="http://pictureposter.audiworld.com/53905/aux_socket3.jpg">

Notice in the picture that part of the spade is still showing. This was a trial fit. I then filed the shoulders off the spades and they now fit deeper into the socket and do not leave any exposed bare metal outside the socket.

I did investigate cannibalizing a second wire harness for the cigarette socket and then splicing together the new harness and the wires from the aux socket. However the harness costs $36.32 (Part #4B0-971-196) so I didn't bother.

Here is a picture of the finished socket in place.
<img src="http://pictureposter.audiworld.com/53905/aux_socket4.jpg">

Boston Driver

I like the OEM look of the VW cap, but good thinking in your project, and much less expensive.

The template is a must. I did mine with 3M Post-it notes, and have it in my black bag for use when I do this mod for others (mine plus two others to date).

I don't have much use for mine now that I have the handsfree cell phone kit, but handy to have for the future.