Roomba Repaired!- New Brush Retainer for Roomba Discovery

[Dr. Roomba]

The pictures submitted by Dr. Roomba have been posted here.
--------------------------------------------------------------------------------------

For those of you like me that has a neutered Roomba Discovery, where you had to send in the brush retainer to get a new one sent to you, thus rendering the "bad" one useless- do not despair!

I had a problem where the rubber brush over-heated and solidly melted into it's socket. iRobot's warrantied replacement process was undertaken, and I diligently sent in my brush retainer for the old one to get a new robot. After time, I decided to attempt surgery to removed the melted brush, which was successful, but required the complete removal of the gearbox to apply the massive amount of pressure required to break the brush free yet not to break everything else. It broke free cleanly and was usable again. Now that the Roomba was "fixed", it didn't matter- there was no brush retainer to hold them in!

Last evening, another project was undertaken, and in 2 1/2 hours using a piece of coat hanger, I meticulously created a precision, reusable "clip on" brush retainer that holds the brushes in PERFECTLY, and removes in a snap so that the brushes may be removed and cleaned as normal. The new retainer works just as if it was made for the Roomba!

Since I have no method of uploading a picture, suffice it for me to describe briefly the premise of the retainer clip;

1. Looking at the bottom of Roomba, and using a peice of coat hanger, create a small hook in the coat hanger that latches on to the front right hook where the original brush retainer clipped on, directly in line above where the yellow bearings on the brushes lie.

2. Using needle nose pliers and the patience of a craftsman, mimic the angles of the depresssions of the areas by the yellow bearings so that the coat hanger lies straight across ONLY the small tabs of the bearings, while also slightly forcing into the tabs, both from the top and the side. Patiently creating the retainer in this manner will allow for little side-to-side or up-and-down "slop" of the retainment of each bearing on the brushes. Yes, this takes time, but it CAN be done.

3. After meticulously creating the retainer across both bearings, heading straight back to where the dust bin mounts, angle the wire straight down (towards the top of Roomba) over the edge from where the rear bearing is, then create a slight hook in the wire that will clip into the void that is actually the top of the black plastic deck the brushes are mounted in.

As described, this took me 2 1/2 hours to carefully create, but with care, this retainer can be fashioned and is EXTREMELY tight and durable, giving new life to a formerly "neutered" Roomba! Test drives prove it's fully functional!

As a side note, to avoid "plastic-to-plastic" melting of the brush ends into their sockets, I have lubricated both bearings, all sockets and all brush ends EXTREMELY LIGHTLY with silicone grease. This should prevent future bonding of over-heated parts.


Good Luck!

Dr. Roomba

[Guest]

nice work.

[RogersRanger]

My wife found your example at about 11:00 last night, and showed it to me, thinking that this would make a great weekend project.

I decided it would be a good NOW project. I grabbed a coat hanger, and literally 10 minutes later I had it finished.

I am waiting for my 3rd roomba to be shipped to me, but in the meanwhile, my FrankenRoomba made from the parts of the two dead ones is now merrily working on my floors. Thanks for the inspiration.

I also found out why my last roomba went bad. It seems that the gears that run the brushes were pushed out of whack by a disgusting amount of hair and other junk that had worked it's way into the gearbox.

[krkeegan]

This is off the original topic, but I see you commented on opening the gearbox. I was wondering if you could describe how you did this.

Kevin

[Rob Zombie]

Perfect! I followed the instructions and had my old roomba up and running in 15 minutes.

Now to figure out what to do with my new frankenroomba...

[RC Eden Carpet Cleaning]

Thanks for giving the instructions I followed them exactly but instead of the coat hanger I used a large sturdy paper clip which I think is easier because there is much less cutting to be done. (and you don't waist a good coat hanger)

[Guest]

You are a clever person. Your Mom must be very proud of you.

[dailo]

I'm having a hard time making this for some reason, how are you guys making it able to clip it to the bottom? It seems like its too loose, doesn't hold the brushes in very well.

[RC Eden Carpet Cleaning]

Ya mine just clips in and out and it holds the brushes just fine. Sorry I can't think of any advice on how to make it clip and hold.

[weyus]

Really helpful - I can't thank you enough.

[dailo]

Could someone help me make one? I can't seem to make one at all after many many tries. It just doesn't fit right, I can't seem to mold the hanger to fit the clips. I'd be willing to pay someone.

[mhanton]

I used 2 zip ties though the hole that the guard clips on

[sogviamask]

That zip tie thing is awesome. Mine was probably the easiest. Swiping the retainer off of a store floor model...

[0bod]

Bump!

[MechanicalMan]

I'm having a hard time making this for some reason, how are you guys making it able to clip it to the bottom? It seems like its too loose, doesn't hold the brushes in very well.

I am trying thus now an I noticed that not all hangers are created equally. It may be that your wire is too small a gauge. In other words, look for a hanger with thicker wire.