Wait, so the "exit" of the teflon tube, the part nearest the hotend, is only 2.5mm in diameter? That's... not good. I'm surprised you're able to print at all to be honest. I know that there were a few cases on the original where people reported that the teflon had deformed slightly over time to cause it to be a bit too restrictive.
I guess it has to be a very short part of the piece that is actually at 2.5mm? If you push a piece of PLA through it, can you make it go through all the way (when cold)? The only way I can see how you have been able to print at all is if it's just a small lip at the end and that the end gets hot enough to heat up the PLA so that it can squeeze through (while at the same time deforming the teflon outwards perhaps?).
Regardless, unless my 1AM brain is completely incompetent that is definitely incorrect and I would use a 3mm drill bit to open it up.
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Ok here we go......
This clog was the worst by far. I started out by trying the change filament option via the controller. Nothing but grinding away the filament is what happened. I tried heating up the hot-end to 250 degrees Celsius and then tried removing the filament via the control panel and with a slight pressure of me pulling the filament with no success. I also tried move material but the filament was already grinded away inside the extruder. So what else is left? Taking apart the hot-end to see what is going on.
I usually start by taking out the 4 side fan screws and I tie up the fans and brackets to the axis rod so I get them out of the way and prevent the wire shielding to get heated up by the heating element.
Then I made sure to mark with a pen, the distance the Bowden tube is sitting inside the Teflon fitting. You can see the line marked with 3 dots which is not exactly against the Teflon, but close enough for reference.
I then loosened all 4 screws out of the aluminum bracket holding the nozzle in place and every other time so far the Bowden tube has come out without a fight. This time was different. I had to heat up the hot-end starting at 190 and gradually moving up to 250 degrees celcius until I could finally loosen the Bowden tube up enough to pull it out.
This is how the filament looked once I got it out.
Then I cut off the filament so I could get the Teflon fitting to go back on the Bowden tube to make sure it is sitting all the way down.
It's perfect no issues here.
Next I took the Teflon fitting and observed it very closely only to find that there's a lip inside the end that is seated into the metal hot-end nozzle adapter. I took my digital caliper and measure 3mm in diameter for the opening at the top of the Teflon fitting and 2.5mm for the diameter at the bottom of the Teflon fitting.
This I noticed once before but didn't think to measure it, but there is definitely some orange plastic stuck inside where the lip is and extremely hard to remove. I would like to razor knife the lip or drill it very carefully, but I need confirmation before doing so if it's not normal.
I then cleaned out the nozzle and saw light through it, which is hard to see in the pic.
Everything else looks great and I can't find anything wrong here besides the Teflon fitting.
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