Topic: 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!!