illuminarti,
Thanks! My extruder is the old one with a screw to turn. I'm afraid I may either be turning it too hard or not turning it enough. I do see marks on the filament where the extruder gear is scoring the plastic filament, which leads me to believe at one point or another it was too tight. As for pulling the filament back out, I've had no luck with this. Even had the head up to 250 degrees, but the filament just seems stuck. I was able to manually push some filament through but it took a lot of force (I'm guessing more than 5lbs).
More trial and error scheduled for tonight. As soon as I get this thing printing I'll build the improved extruder assembly and get it in place.
Memphis, TN?! I almost moved there earlier this year for work. Was working for Games Workshop at the time and they are headquartered there. Good BBQ.
If I get stuck again tonight I'll post with pictures.