I modeled and 3D printed this replacement part it several times at the local library. I've made the final design available for printing at www.shapeways.com (See link below). Of course, you can also model your own design if you wish to spend the time.
Shapeways BCG800XL Impeller Shop
Here's a video with some background on the Shapeways part.
After nearly 2 years of roughly 3-double shots per day (~54 grams per day) , I did a full teardown to see how the design was holding up. I am very happy with the results, and you can see the full details here.
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