Dyson Big Bin Runner repair

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asavage
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Dyson Big Bin Runner repair

#1

Post by asavage »

Dyson's V10 & V11 cordless vacs . . . I love 'em. Currently, I've got one V10, one V11, and one V11 Outside (bin is longer and larger diameter).

Recently, I broke the stop on the "Big Bin Runner", (really the name) part No. 969835-01, of my V10. Turns out, this is a very common problem: the molded stop lip of the Big Bin Runner breaks off if you slide open the bin too vigorously -- and I do. When the stop lip breaks off, and when you go to empty the bin of debris, the bin can slide off the main unit. While the bin is normally removable like this, it's also normally restrained by the stop lip, so you have to push an add'l tab to allow complete bin removal.

I was able to buy a couple of replacement Big Bin Runners that fit the V10 and V11 (not the Outsize, though) for $20 ea., and it's not terrible to replace, if you have tools. There are even YT vids to guide one. But the replacement part is no better designed/reinforced than the original. I can be careful when emptying the bins, but I prefer a more robust design. As an experiment, I played around a bit.
Dead Amazon page where Dyson Big Bin Runner 969835-01 at one time could be purchased.
Dead Amazon page where Dyson Big Bin Runner 969835-01 at one time could be purchased.
Dyson_Big_Bin_Runner_969835-01_01b.png (851.8 KiB) Viewed 1473 times
Dyson Big Bin Runners 969835-01: New on top, broken below.
Dyson Big Bin Runners 969835-01: New on top, broken below.
Dyson_Big_Bin_Runner_969835-01_02b.jpg (1.31 MiB) Viewed 1473 times
Dyson Big Bin Runners 969835-01: New on right, broken on left.
Dyson Big Bin Runners 969835-01: New on right, broken on left.
Dyson_Big_Bin_Runner_969835-01_03b.jpg (718.72 KiB) Viewed 1473 times
Dyson Big Bin Runner 969835-01: New, closeup.
Dyson Big Bin Runner 969835-01: New, closeup.
Dyson_Big_Bin_Runner_969835-01_04b.jpg (1.05 MiB) Viewed 1473 times
Dyson Big Bin Runner 969835-01: New, closeup.
Dyson Big Bin Runner 969835-01: New, closeup.
Dyson_Big_Bin_Runner_969835-01_06b.jpg (500.75 KiB) Viewed 1473 times
Dyson Big Bin Runner 969835-01: broken, closeup.
Dyson Big Bin Runner 969835-01: broken, closeup.
Dyson_Big_Bin_Runner_969835-01_05b.jpg (690.05 KiB) Viewed 1473 times

A replacement aluminum tab could be fashioned to be affixed to the inside curve with two screws and acorn nuts.

Dyson Big Bin Runner 969835-01: repair stop.
Dyson Big Bin Runner 969835-01: repair stop.
Dyson_Big_Bin_Runner_969835-01_07b.png (53.18 KiB) Viewed 1473 times
Dyson Big Bin Runner 969835-01: repair stop.
Dyson Big Bin Runner 969835-01: repair stop.
Dyson_Big_Bin_Runner_969835-01_08b.png (16.2 KiB) Viewed 1473 times
Dyson Big Bin Runner 969835-01: repair stop.
Dyson Big Bin Runner 969835-01: repair stop.
Dyson_Big_Bin_Runner_969835-01_09b.png (4.69 KiB) Viewed 1473 times
Dyson Big Bin Runner 969835-01: repair stop.
Dyson Big Bin Runner 969835-01: repair stop.
Dyson_Big_Bin_Runner_969835-01_10b.png (36.17 KiB) Viewed 1473 times
Dyson Big Bin Runner 969835-01: repair stop.
Dyson Big Bin Runner 969835-01: repair stop.
Dyson_Big_Bin_Runner_969835-01_11b.png (27.05 KiB) Viewed 1473 times
Dyson Big Bin Runner 969835-01: repair stop.
Dyson Big Bin Runner 969835-01: repair stop.
Dyson_Big_Bin_Runner_969835-01_12b.png (38.46 KiB) Viewed 1473 times
Dyson Big Bin Runner 969835-01: repair stop cost to fabricate part.
Dyson Big Bin Runner 969835-01: repair stop cost to fabricate part.
Dyson_Big_Bin_Runner_969835-01_13b.png (11.5 KiB) Viewed 1473 times


The part shown is .050" thick, both curved part and end stop. It's drilled and counterbored for two 4-40 x 3/16" wafer-head screws. Wafer-head screws are like cheese-head or filister-head, but with a much thinner (shorter) head, good for tight spaces. $0.33 ea. if you buy (100) = $33.

Wafer-head screw, 4-40 x 3/16"
Wafer-head screw, 4-40 x 3/16"
Dyson_Big_Bin_Runner_969835-01_15b.png (218.99 KiB) Viewed 1473 times
Wafer-head screw, 4-40 x 3/16"
Wafer-head screw, 4-40 x 3/16"
Dyson_Big_Bin_Runner_969835-01_14b.jpg (6.82 KiB) Viewed 1473 times
Next, to anchor the screws, 4-40 acorn nuts. These have a threaded depth of just shy of 1/8", which should be perfect for our wafer-head screws' length. About $90 for (500) minimum qty. from that vendor.

Acorn nuts, 4-40, 18-8 SS
Acorn nuts, 4-40, 18-8 SS
Dyson_Big_Bin_Runner_969835-01_16b.png (366.73 KiB) Viewed 1473 times
Acorn nuts, 4-40, 18-8 SS
Acorn nuts, 4-40, 18-8 SS
Dyson_Big_Bin_Runner_969835-01_17b.png (328.05 KiB) Viewed 1473 times

Lastly, one needs a #32 drill bit to create a hole in the plastic to clear #4 machine screws. HomeDepot has inexpensive ones, $5 for (12).


Rough costs for make (100) "kits" to repair these $20 Big Bin Runners:

Stop: $613 for (100)
Screws: $33 for (100)
Nuts: $90 for (500)
Bits: $45 for (108)

That comes to $781 to make (100). I'm sure there's some minor shipping or tax costs not included there.

While the cost to make subsequent batches would be less (no setup fee, for example), there's also no guarantee that I got all the dimensions and parameters perfect, and the cost of (1) as a prototype is $284.

Nah, I don't think I'll go into production. But it was a fun afternoon thinking about it.

Notes:
* The area where the acorn nuts would be is not a place where hands normally go, so no need for a smoother design.
* Inside-of-curve clearance looks ample for .050" material.
Regards,
Al S.

1982 Maxima diesel wagon, 2nd & 4th owner, 165k miles, rusty & burgundy/grey. Purchased 1996, SOLD 16Feb10
1983 Maxima diesel wagon, 199k miles, rusty, light yellow/light brown. SOLD 14Jul07
1981 720 SD22 (scrapped 04Sep07)
1983 Sentra CD17, 255k, bought 06Jul08, gave it away 22Jun10.
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