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Originally Posted by 5.2
REPLACEMENT PARTS - A COMPONENT or MECHANISM constructed as a functional duplicate of an existing part of the robot, for the purpose of replacing a broken or defective part. REPLACEMENT PARTS may be either COTS or FABRICATED ITEMS. They must be functionally identical to the original part but may be modified to provide more robust performance of the function.
Example 1: A lever arm made of lexan on your robot breaks. You manufacture a REPLACEMENT PART made of aluminum plate, using the design drawings of the original. As the new part provides the same function as the broken part, the new part is a valid REPLACEMENT PART.
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This is where I'd have to look at the arm myself. If it's the same arm, but a different material (which could very well change the weight), then it fits the definition of a replacement part. If they noticeably changed it and there's some new doo-dad on the end, then it's not a replacement part, and it's time for a do-over.
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I think the rule pretty clearly says this is legal. Remember that a PART can be both a COMPONENT and a MECHANISM. The arm is a MECHANISM. It can be repaired or upgraded. The arm is still going to provide the same functionality, namely picking up and stacking tetras. It does not matter whether it has a new doo-dad at the end. Parts may be upgraded. As long as they have 25 lbs or less of total manufactured parts, they are legal. They don't have to disassemble their arm.