The SECRET is fans!!!

Been dallying with this 'contraption' since Christmas.  Broke a part, clogged another part, got it all back together, and based on recommendations and talk from here, ordered 40mm fans from Ebay.  Got 6 of them for .99 each! (free shipping too - big spender!) Came from who knows where - got here yesterday.  During the interim, I printed, after many tries, a Y axis stepper motor slip on mount, a nozzle slip on mount that mounts to the little piece of plywood, and a plate that accepts 2 fans that replaces the clear Lexan cover for the PC board. 

I originally ordered the base model with no heated bed, and as such got a small 12VDC power supply.  I have since upgraded to the larger PS and heated bed, and now use the smaller PS for the fans.  They all connect to it thru a terminal strip stuck to the back of the machine.  Works great. 

Got a few pieces of plain window glass, a little spritz of hair spray, and off we go..... All is well in Muddville - for now!!

Have now been printing for some 4 hours non-stop with NO errors!!