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.
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- Dyson Big Bin Runners 969835-01: New on top, broken below.
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- Dyson Big Bin Runners 969835-01: New on right, broken on left.
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- Dyson Big Bin Runner 969835-01: New, closeup.
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- Dyson Big Bin Runner 969835-01: New, closeup.
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- Dyson Big Bin Runner 969835-01: broken, closeup.
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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.
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- Dyson Big Bin Runner 969835-01: repair stop.
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- Dyson Big Bin Runner 969835-01: repair stop.
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- Dyson Big Bin Runner 969835-01: repair stop.
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- Dyson Big Bin Runner 969835-01: repair stop.
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- Dyson Big Bin Runner 969835-01: repair stop.
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- Dyson Big Bin Runner 969835-01: repair stop cost to fabricate part.
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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"
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- Wafer-head screw, 4-40 x 3/16"
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- Acorn nuts, 4-40, 18-8 SS
- Dyson_Big_Bin_Runner_969835-01_16b.png (366.73 KiB) Viewed 5181 times
- Acorn nuts, 4-40, 18-8 SS
- Dyson_Big_Bin_Runner_969835-01_17b.png (328.05 KiB) Viewed 5181 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.