Now that we had another convenient way of cleaning the floor, I took advantage and took poor old room-bot apart. I knew that this process would take several days (and with several days in between when I had the chance to work on it, it would likely be a few weeks before room-bot had completed his recovery).
has a good set of pdfs documenting the disassembly/reassembly procedures. They also have reasonable prices on used and new parts, but I'm extremely cheap, so I thought I'd give it a try on my own. I referred to http://www.robotshop.com/PDF/roomba-disassembly-discovery.pdf
through the repair. I also used clear tape to affix screws to parts in order to keep everything organized.
Because the assembly procedure is so well documented, in a much more thorough manner than I could do here, I have skipped the disassembly and reassembly steps. Just be sure to keep yourself organized, and it's fairly straight forward as to what goes where. If you can't keep track of that stuff, this 'ible is probably too advanced for you.
As you're disassembling, it's a good opportunity to get rid of any little hair clumps or dirt that's really jammed in there. With five hairy animals at home (and that doesn't include me), I periodically do this just to keep the machine running in top shape.
The possibility of doing this on my own without spending a bunch of money on specialized equipment was made clear when I read mikey77
's 'ible on Oogoo
. Turns out, I have everything
I need to do this fix, without spending anything!
Finally, a small caveat to this instructable. This was my first time ever making a mold and casting a part. I made some mistakes. I will attempt to describe what I did wrong, and what I believe would improve the process, if you decide to do this. However, if you know better, or have different ideas, please don't take this instructable as direct instruction. It's intended more as a journal of what I did, and what you might want to try, as well.