dvhart wrote:OK, I've given up on Breville supplying a replacement part. Maybe they'll make the group head service kit available at some point in the future (seems you can get some places to provide a quote for it for $190 USD). In the mean time, I am attempting to create a printable replacement part. I've only just started the model and it's my first one. But I'm making it publicly available:

https://github.com/dvhart/scad-models/b ... t-gen1.stl

<img>

I've received one example print, and to my surprise, it actually worked (print: left, original: right):

<img>

I don't know how long it will work, 3D printing materials vary considerably in heat resistance, friction, durability, deformation, etc. The idea is to iterate on the model until it's a reliably good fit, and then experiment with materials. Once I have a known good model and reasonably performant material, I'll report back with that info. Shapeways.com can print this model today for $10-$70 depending on the material in case anyone wants to help develop the model (but please understand it is still under development).

Really excellent work. You are leagues ahead of me in the DIY department. I was however successful in getting a free service out of Breville. They are sending me a Return Shipping Box and covering all associated costs, including the potential replacement of the machine with a 920XL. Now this next part is why, and perhaps a stroke of luck.

July or August of 2017 I picked up a bottomless portafilter from SGC. Upon arrival, I could not for the life of me get the thing to seat into my group head. It felt as if i was trying to force it. So I called Breville and they advised me to use a bit more force and see if it would seat in after a couple of uses, they even had me make a YouTube video of the portafilter not locking in correctly. Eventually they sent out a new porta and chalked mine up to being built out of tolerance. The replacement did function as intended.

Shortly after the above incident, is when I started to notice a random drip of hot water around my portafilter when pulling a shot, maybe every 3-4 shots Id get a drip or three of clean water down the side of the porta-filter. I didn't immediately deduce that the whacky porta filter being too big, and my leak, could be related. This leak got exponentially worse as time went on, and got to the point of "I can't toelrate this anymore" when I made the original post.

Yesterday, I called Breville and it literally clicked as I was on hold. I had to sell my story a bit, but nothing that wasnt clearly logical, or even a lie. They provided me with a porta filter that was out of spec, it stretched my group head collar, and now my machine leaks as a direct result. I couldnt be expected to foot the bill for a service for that, right? Well luckily the guy took pitty on me, and got the service order iniatiated after talking with his supervisor. The supervisor did review the initial case regarding my porta filter to see I wasn't just blowing smoke, and while he probably could have still chalked it up to being a "wear item", I am thankful Breville is ultimately willing to help me out.

So that's my story thus far, Im crossing my fingers that a refurbed 920 arrives back to me in a couple weeks, as the water in my area is incredibly hard and I would like to have a machine I could descale myself if needed. I'll keep updating this as needed. Good luck to you @dvhart!

That's a much better solution for your situation @chubbyone! I hope that pans out for you.

I have continued to improve the model I posted above, and to my surprise, the first print actually worked. I've had 12 successful pulls so far, and will start experimenting with materials and I find one that is a good balance between hardness and flexibility.

Well, my Dual Boiler is on the fed ex truck for delivery this morning. They sent back my machine repaired, so I am eager to see what was changed/fixed. Hopefully they include a service report in the package.

Will report back!

Thanks. As a BDB owner, I am always eager to see how they take care of other owners that need service.

dvhart wrote: I don't know how long it will work, 3D printing materials vary considerably in heat resistance, friction, durability, deformation, etc. The idea is to iterate on the model until it's a reliably good fit, and then experiment with materials. Once I have a known good model and reasonably performant material, I'll report back with that info. Shapeways.com can print this model today for $10-$70 depending on the material in case anyone wants to help develop the model (but please understand it is still under development).

Thank you for getting this started! My Oracle has the same problem, but Breville charges a flat $500 to replace the $3 part instead of the $350 they charge for a BDB. (!!!)

I'm an ME and have access to an FDM. I downloaded your model last night and printed a copy.



Now I need to open the Oracle and test fit it. Once I have the original part out, I will also give that a thorough inspection. If I find areas to improve, I will be sure to share with you. (I'm likely to recreate the part in Solidworks to have a model I can tweak on.)

lancealot wrote:Thanks. As a BDB owner, I am always eager to see how they take care of other owners that need service.

No problem!

The machine arrived back in the same box I sent it out in. With the power cord nested back Inside the side panel as original. The box included a simple service checklist that insured the machine pressure, volumetric controls, and seals were all functioning as they should, and that the unit had been de-scaled and drained. Firing it back up the first time, the boilers and pump were a little slow to prime and push the air out of the system. I had to jostle it around a bit to get the air to escape, after that it quiet back to normal.

I have not been able to test the seal other than run a cleaning cycle. I have had a stomach bug and espresso is the last thing my gut needs at the moment.

I can however notice a drastic difference on the physical force needed to lock the porta filter in the perpendicular to the machine position, so there is definitely a new seal in there. I don't believe they replaced the whole group head, and don't plan to take the machine apart to actually see it. At least not I ol I have an issue again.

Thanks to the 3D printer folk chiming in here! I am surely going to save a copy of those files and keep an eye on the materials you guys test.

Thanks everyone!

Machine is going strong again, I have noticed a couple drips from the steam wand that I don't remember before, maybe the descaleing they did opened up some gaps in places that were previously crusted over? Just spitballing there.

I pull 2-4 straight shots daily, so I am happy enough to have that functionality back to normal. Gonna continue to run this thing into the ground with daily use and see what Breville will do next time something goes wrong. Sadly i think the reality is that it will be sooner than later, however, If they continue to be as willing to help, I'll stick by them. Too much value outta this machine so far not to! (Mind you I purchased this at $300 used, and they supported my service claim regardless of knowing I purchased it second hand)

Cheers!

mmakay wrote:Thank you for getting this started! My Oracle has the same problem, but Breville charges a flat $500 to replace the $3 part instead of the $350 they charge for a BDB. (!!!)

I'm an ME and have access to an FDM. I downloaded your model last night and printed a copy.

<image>

Now I need to open the Oracle and test fit it. Once I have the original part out, I will also give that a thorough inspection. If I find areas to improve, I will be sure to share with you. (I'm likely to recreate the part in Solidworks to have a model I can tweak on.)

Any updates to the design.
Thanks

I tweaked it and made it fit quite well. I'm confident that the geometry works. I tried a couple different 3D print materials, though, and they just don't hold up. The original is molded from a glass reinforced plastic that can't be replicated (yet). If you were to have it machined from metal, I think it would be perfect. Brass would be my choice. Cost becomes a serious hurdle at that point.

What I ended up doing was even more McGyver. I ordered the updated group head for a BES900 from eReplacementParts for a little over $100. It takes the new & AVAILABLE split collar inserts that can be replaced without opening the machine. The mounting points for the boiler have moved (2 of 3, anyway) so I had to do some drilling and use spacers. But otherwise, the group collar is a direct fit. The rest could be made to work if you needed it to, but more work would be required as they messed with the plumbing a bit. I did use the new shower screen and seal, though. It also came with a new portafilter handle that will probably become bottomless sometime soon.

Couple of points and ideas...

1) First of all, some of you are already on to this first one, and that is that there was a mid-cycle design change to the -900 family, the main change being a change to the group, to a new design that would eventually carry over to -920 family. If you kept your box, it might have said something with a /B at the end, as in BES-900XL/B or the like. If you have this version, you can order the -920 group collars from ereplacementparts.com.

2) Longer-term ownership strategy... If you have had a BDB, any BDB, (-900 family or -920 family) for over three years, you will have done or need to do some routine underhood maintenance: replace the o-rings under the tubes on top of the steam boiler, replace the three way solenoid, replace the steam ball valve. The size #007 o-rings are ten cents a piece including shipping from Amazon. The other two are nominally $50 each. That is all I have ever needed to keep my BDB running since fall 2011. I realize that I may be on borrowed time with the plastic collar however. I do make it a point to only tighten the portafilter just barely tight enough to prevent spinout. And making sure that gasket and rim of the PF
are bone dry, allows you to do that more effectively.

My strategy for now is, if I ever need to bite the bullet and send in for the $350 repair service, I'm going to put back my old failed solenoid and old leaky steam ball valve, so when I get it back repaired or replaced, it will have a new solenoid and steam valve... About $100 worth of gear you were going to need anyway for long term BDB ownership.

-Peter