Mixed Emotions....

After several nozzle failures I have a design that seems very robust and made several acceptable prints.

But then more trouble...

Most of the PLA prints have decent shells but the infill is spotty at best.  The extrusion seems to just slow and stop then start again. I tried some ABS I had and that seemed to extruded a little better but the layers did not stick.  I think that is a setting issue but I have not tried adjusting that yet.

As far as the PLA goes I have now tried turning up the heat, down the heat, oiling the filament, manual feeding, adjusting the tension on the Wade's extruder, adjusting the current...  But no luck after the initial success.  The one good thing is that the new nozzle design has not fallen apart and seems very strong.

I have some more ABS so I plan to try adjusting the settings and seeing if I can get the ABS to extrude consistently. (Although I hate the smell and the warping issues with ABS, but I will live with them to diagnose my problem.)

Good News, Bad News...

I will start with the bad news.  I broke my new nozzle. :-(

I am not sure what I am doing wrong.  I wrapped it once hooked it up and it seemed to not be heating up very well.  When I took it apart and looked at it I realized that I had wrapped the nichrome too close to the tip.  I was directly heating the thermistor, and managed to crack the glass bead. :-(

You can see how close to the tip I wrapped the wire in this picture.

I then re-wrapped the heater with the nichrome more in the middle.  And once again tested pushing the PLA through by hand first.  It had some back pressure but I could push it through.  So I hooked it up to the extruder and tried running it.  It seemed to have some trouble (like it was not hot enough) so I turned the heat up from 180 to 190 and the filament started coming out like it did with my first nozzle (before it had failed).  Then disaster... the nozzle slid out right before my eyes... it just slid all the way out, even with the pipe clamp on the PLA.  Looking at the threads of the brass one can see that they are filled with PLA...

I guess I will have to try again.  But it will probably be a few days as my schedule is getting a little full...

Now for the good news. (actually two bits of good news :-)
First my black-light post was picked up on Fabbaloo and Make: Online. Very cool :-)

Second I designed a wiring block for my Mendel that makes wiring the extruder to the boards much easier.  Which has turned out to be a good thing since I have had to rewire several times and still may have several more...

As you can see it just press fits on the three screws closest to my boards.  The coat hanger supports and guides the wires to the x carriage end.  The idea being that the wires will ALWAYS be out of the way that way.  I caught my stepper wires on my spool holder before... which can't happen with this setup.
You will notice that there is a 9 position terminal block, 4 are for the stepper, 2 for the heater, 2 for thermistor, and the last is just a spare ground.  I also ran a 6 conductor ribbon cable for LEDs (five circuits with one ground).  These are connected to the pins at the front and back: 2 circuits front, 2 back, and a third both front and back.  Watch for some lighting in the near future...

I have not posted formal directions but someone could make one from these pictures.  Once Willow is running again I may write up some directions.