Sounds like my DH. I’d be inclined to take it somewhere to have the legs adjusted to fit a new set of casters. If one shattered that easily maybe they are reaching end of life.

That's a good point. If one shattered maybe the other three aren't going to last forever either. Would it be a furniture repair shop that could reshape the legs to fit new cup casters?

The other two cup casters that I ordered were these.

This is the one with the smaller wheel and shorter cup:

https://www.osbornewood.com/products/brass-cup-caster-1

This is the one that's taller and brighter brass:

https://www.houseofantiquehardware.com/brass-furniture-wheels-round-cup-abh

The weight / sturdiness of this second one seems superior to the original and to the first one I ordered. (It was also $50 instead of $10 so that makes sense.)

Maybe I should try ordering maddieliee's VanDyke's suggestion next and see how that one fits. And then pick the best of the bunch and order enough for both chairs and find a local shop if the VanDyke's isn't a perfect fit either.

Did you see this one, it seems an in between size to the two you have ordered

https://www.vandykes.com/restorers-round-cup-caster/p/200527/s/02217424/?utm_source=google&utm_medium=cpc&utm_campaign=ppc_google_pla&gad_source=1&gclid=Cj0KCQiArrCvBhCNARIsAOkAGcXst7tuZV4ljOYdMX0Wra6w9qxoODKqL-SeiC0jVu83qvbT5VpZ1rMaApLMEALw_wcB

I would take the broken caster to a welding shop and see if it can be repaired. A local upholstery shop might be able to suggest someone or other options.

^^^ Yes, try. Who knows.

It looks a bit like ”white” or ”pot” metal which can be near imposible to weld. Bt, you never know, technology moves ahead.

PS Slap your DH for me ;)

Yes my first thought was also to go ahead and replace all four both for height and appearance.

Do you need casters on the chair? Maybe remove all four.

Measure the diameter of the top of the castor, then buy four new ones. Until you can find them, I would just remove all four, as Maggies suggested above. I would not trust fixing it.

Thanks Oly and petalique. I wasn't sure what kind of shop might be able to do something, but I'll see if I can check out welding shops. Part of my concern was the type of metal, but also part of the bracket seems to have completely shattered on one side. (You can see in the second picture that the corner seems to be just gone.) Not sure if someone could build it back up. I wish I could take apart the casters and somehow swap the cup of my original onto another caster bracket/wheel.

I suppose I could take the chairs into a shop and have them replace the legs with something tall enough without casters, but the casters are part of the charm of the chair. So I'd rather try to repair or replace them if possible. Just removing the casters drops the front legs so that they're uneven with the back legs. This is a picture of the chairs.

I used a caliper to measure the cup and the top interior width at 1.43 which is 1 7/16 (and checked with a ruler as well). It's more difficult to measure the inside bottom of the cup since my caliper isn't long enough to reach the bottom. The two options I already purchased do partially fit onto the base of the leg, but they don't slide all of the way on. I think the cups must have a different taper.

localeater, I think I might try to order one or both of the VanDyke's options that seem close. (One is listed at 1 1/2" cup diameter and the other at 1 1/4" and mine seems to be between.) Maybe third (or fourth) time will be the charm.

Thank you for the ideas of having all four casters replaced. It seems like a good option if none of the casters are just right. I think someone (even me maybe) could taper the legs to get them to fit one of the replacements.

I ran into the same problem. Swapping all the casters for matching ones is usually easier than finding a single exact replacement.