Eureka AirSpeed AS1104A Brushroll Pully/Pulley (all AS1000 stype brushroll assemblies)

thingiverse

The Eureeka AirSpeed upright vacuum cleaner, specifically the AS1104 model, comes with a lever switch on its side that tightens a belt between the motor driveshaft and an intermediate pulley. This pulley drives another notched belt connected to the actual brushroll. The design is more complex than the previous "on/off" actuation switch found in older Eureeka upright models but offers the advantage of a large externalized switch with two distinct positions for on and off, easily activated by a foot. The problem with this design is that it has more failure points due to increased complexity. In my case, the molded plastic pulley suddenly snapped in half on my machine (black pulley in picture - glued together for measurements). After searching in vain for the pulley, which Eureeka never sold separately, I discovered that even the brushroll "on/off" assembly containing the 50-cent pulley is discontinued everywhere. This is a result of just-in-time inventory and disposable parts production cycles for durable goods. Repairing the vacuum would cost labor, but my mantra has always been "If I can't fix it, then either it's not broken or I need to break it more and figure out how to fix it." Indeed, this pulley can be used to repair assembly part number 84708 if that's what you're looking for. Rather than throwing away the beautifully performing vacuum after ten years, I decided to 3D print the pulley. My efforts are detailed in the files below. Version 2 of the design successfully repaired my vacuum, but it required some fine adjustments with a Dremmel rotary sander and a mini rate-tail file. Version 3 of the file incorporates these modifications into the design for less manual adjustment. I include the .SCAD file as a courtesy to anyone who might prefer to make fine adjustments rather than using sandpaper, files, and acetone. I want to caution users that my part made with PLA initially had an issue with the shoulders melting and collapsing, causing the belt to become jammed. This is because the belt gets hot under normal operation and can soften the PLA. While I would love to print this part with ABS or Polycarbonate for heat resistance, it's not possible. If you use PLA like me, be aware of the risk of softening to the part. If you're working on this repair and need guidance, feel free to message me. If the platform alerts me, I'll respond promptly; otherwise, I'll respond when I come back here to post my next project file.