Update: This Instructable was featured on lifehacker.com! Visit the article here.
The wheel on my favorite carry-on bag had a chunk come off of it one one trip and it wasn't too many trips later that the plastic part of the wheel came off completely, leaving behind the little metal core that housed the bearings. This left me scraping through the terminal and carrying the bag through anyone's house as to not leave a trail of scrape marks behind me. Other than the wheel the bag was in fine shape so I hated to throw the thing away. Here's what I did to repair it. You can see this repair and more than 100 others at my blog at johnfixesstuff.com
Step 1: Bum Wheel
Here's what I eventually was left with on my carry-on bag--a bum wheel. It changed the meaning of carry on to "always carry" because the thing sat crooked and was obnoxiously noisy too. Now, if you only have a chunk out of your wheel like I did originally you may need to go ahead and put the thing out of it's misery and just pry off the rest of the wheel so you are left with a round base. I don't think you can do anything with the lumpy wheel unless you want to try to build it up with something but that's for another instructable.