I disassembled Aaron’s hotend on live stream and I learned a lot.
1. Based on general assembly guidelines of a stock e3dv6 the nozzle was between 0.40-0.45mm away from the heat block. 0.30 or less is more typical but nothing to be shocked about.
2. His extruder was built very well. Nothing wrong in assembly whatsoever.
3. After removing everything I’ve found the jam happens right above the prusa step on their custom heatbreak.
4. Where the step is the filament should be cool already but the bulb was and as you can see large and quite a bit above the step.
I don’t know what to process here just yet besides the cooling sucks and the step gets in the way when the cooling sucks. I’m going to try and get one more hotend just like this that’s already jammed and confirm the findings then move forward with possibly making chamfered MK3s heartbreaks where the step isn’t actually a 90 degree step.
At this point if you’re having issues and even better cooling doesn’t fix it then get yourselves a stock e3dv6 heatbreak in the mean time.