🧳 How I Fixed My Berghaus Mule 100 Wheel with a Hacksaw and a Bolt (DIY Luggage Repair on the Road)

I fixed my Berghaus Mule 100 on the hotel balcony in Thailand with nothing but basic tools and a bit of determination.

When you travel full time, your gear takes a beating. Our trusty Berghaus Mule 100 wheeled holdall finally had a wheel fail after it had shattered one too many pavements. Instead of binning it or paying for a repair, I decided to fix it myself with nothing more than a hacksaw, a flathead screwdriver, and a 4 cm bolt from a local hardware store.

🔧 What Happened

The original wheel had cracked so badly it was barely hanging on. The axle pin was also worn and starting to pull loose. With no repair shops nearby, I picked up a basic hacksaw and spanner from a hardware store next to our hotel and a replacement wheel set from a local skate shop.

🛠️ How I Did It

The process was surprisingly straightforward:

Removed the Old Wheel

– To remove the axle, I placed the hacksaw blade between the roller bearing and the case on the axle pin and carefully sawed the pin in half. This freed the broken wheel without damaging the rest of the housing.

– Sourced a Replacement Wheel set I picked up a 75mm x 25mm wheel (from a skate shop in Thailand) that matched the original size. Always measure your old wheel carefully diameter and width both matter.

– Fitted a New Axle which is now a 4 cm bolt with a lock nut to hold the new wheel securely in place.

– Tested It Tightened everything by hand with the spanner. Rolled it around the balcony to make sure it was smooth and solid.

Now the bag is back in action and ready for many more adventures.

✨ Why Share This?

I couldn’t find a single detailed video or guide showing how to replace the wheels on a Berghaus Mule 100. If you have one of these bags and it’s seen better days (or has smashed a few pavements like ours), this simple repair can save you money and keep your gear rolling for years to come and you can do it at your hotel with limited kit!

📹 Watch the Quick Repair Video