1.) You appear to be on to something here, though, I am not sure if its the whole thing. When I did a test print with the fan turned off the under extrusion seems to be reduced. Still present, but reduced. It occurs to me that a difference between the working UM1 at home and this one is that I printed new fan shroud for that one. Is there one you would recommend specifically?
2.) I just replaced the thermocouple so it seems unlikely. If it is the thermocouple it is at the very least consistent. I have watched the temp reading during the print and it never varies more than a degree (Except when the fan kicks on but that is quickly recovered).
How can I tell if it is boiling? Just heat it up and listen and watch for bubbles in the filament as it oozes out of the nozzle?
3.) I have never printed ABS, and as I mentioned the nozzle, brass insert and peak tube are all brand new from UM, so clogging in there from gunk seems unlikely.
4.) I will have to gather some equipment to perform the test you suggested, but I will say that in the past when cleaning the nozzle I haven't ever found any wood debris.
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gr5 2,295
Don't know. Some ideas:
1) Is the fan blowing on the nozzle tip? That can cause underextrusion if it blows directly. I mean could this have changed since a year ago? You didn't show that in your photographs.
2) Maybe the sensor probe is bad - calibrate temperature by heating to 95C and 105C and it should boil at 105C and not at 95C.
3) Do you print ABS sometimes? Switching back and forth can cause clogs.
4) Maybe there is some wood from the feeder getting onto the filament and getting carried through the bowden and causing clogs although likely this would be more serious.
I recommend this test to help decide if the feeder is the problem:
http://umforum.ultimaker.com/index.php?/topic/4222-pulling-force-of-um-extruder/?p=34887
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