Might it help to have the fan come on later? The original rationale for the staggered fan start up on the UM2 was that it blew too much air too close to the bed, and it basically bounced off the bed and cooled the nozzle - which could certainly cause under extrusion.
Also is combing turned off or on, in your settings?
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Underextrusion strikes again :(
I printed the Blockbot (http://www.thingiverse.com/make:15641) scaled at 0.5 and one or two layers didn't print correctly. Later it went on flawlessly.
I thought it might be the filament but the previous model (Low Poly Stanford Bunny - http://www.thingiverse.com/thing:151081) worked perfectly.
What the hell?
George, if it is not too much to ask, would you print the blockbot (plate 1) at 0.5 with the orange filament? Then we'd have used the very same materials/hardware. Here are my print settings:
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