Recently I stumbled on a thread that said that with a 0.40 nozzle the thinnest width should be configured for 0.48, where I had been following someone elses rule of 1.4 x layer height (0.42 for 0.30 and 0.35 for 0.2).  I was finding my prints a bit fraile especially when printing 0.2 height.  So it seems 0.48 is too wide and causing the occasional diagonal catch on the filament.

I really should keep a change log when I adjust things.....

I must really thank you all going through the process with me and your suggestions to help me bring it to resolution.

Now to determine my proper width, back to 0.42 (for all heights) for now....

Andrew

I've experienced this before. Let us hope this is the same issue.

When you watch the print, does the filament lay down in place, but then raise into the place you'ce documented?
Another question: Do you have a case of some sort?

I don't think it is lay down in place, I actually think it's attached at the diagonal with the previous laid down perimeter line on the same layer...  so I don't think it's bouncing up, or is a layer adhesion problem.  I think, happens so fast sometimes it's hard to say.

Yes I do have a case, made of dollarstore foamboard, the last few prints have been without, but it still does it with it, temp on large prints inside reach 40c with the case on.

Thanks
  Andrew

When you watch the print, does the filament lay down in place, but then raise into the place you'ce documented?
Another question: Do you have a case of some sort?

It's not very tight, but not loose enough to skip from what I'm seeing.  I'm no sure it's actually gapping anymore, but where the gap is the extrusion is raised, I am actually seeing it when watching....   No grinding or plugs on the extruder, I'm used to handling those issues,

things I've changed, to no effect;

Raised the Extruder reference voltage to 0.355 from 0.192, definitely squirting more out, need to recalibrate... still have the gaps.
Raised the temp from 200 to 215 for the extruder... still gapping.... 
Slowed down the printer to 50%, standard perimeters were printing at 70mm/s, external perimeters at 35% at normal rate, I changed this during mid print, it seems better, not perfect, but better.....  I wouldn't think 70mm/s would be too fast for ABS perimeters?

Wondering if the filament is crap and this could be a result of that?  Going to try my roll of orange I got from a different vendor.

Thanks
  Andrew

Ok, orange has no positive effect, so it's not the filament... I guess thats a good thing....

Here's a new pic, I hope it shows better what I'm experiencing, I missed catching it before it put the next layer on top of the raised piece, but I think it's still pretty clear, the layer is there, not missing, just, higher, the nozzel is at the right height, I'm getting a great first layer for adhesion, and the z from everything I can tell isn't changing mid-layer.......  I'm going mad.....

How is your tension arm? If it is too loose, the bearing (to the right) will not turn at the same pace as the Nema gear. Thus, giving you random voids.
This is one thing I noticed whilst learning my machine.

EDIT: A dead giveaway of this would be stripping of filament in the extruder. This can also be a sign of a clog, but I don;t think this is the case with your problem.

It's not very tight, but not loose enough to skip from what I'm seeing.  I'm no sure it's actually gapping anymore, but where the gap is the extrusion is raised, I am actually seeing it when watching....   No grinding or plugs on the extruder, I'm used to handling those issues,

things I've changed, to no effect;

Raised the Extruder reference voltage to 0.355 from 0.192, definitely squirting more out, need to recalibrate... still have the gaps.
Raised the temp from 200 to 215 for the extruder... still gapping.... 
Slowed down the printer to 50%, standard perimeters were printing at 70mm/s, external perimeters at 35% at normal rate, I changed this during mid print, it seems better, not perfect, but better.....  I wouldn't think 70mm/s would be too fast for ABS perimeters?

Wondering if the filament is crap and this could be a result of that?  Going to try my roll of orange I got from a different vendor.

Thanks
  Andrew

EDIT: A dead giveaway of this would be stripping of filament in the extruder. This can also be a sign of a clog, but I don;t think this is the case with your problem.

wardjr wrote:

The little white blocks in the rear of the carriage are adjustable just don't tighten them up too much,

Yup, already looked at it, it's main job is to let the carriage move a little the other way, and not the way I have slop, the bushing actually has space and movement on the smooth shaft.... maybe I can adjust the white block on top to push back some more.... but not tonight....

Thanks
  Andrew

Well everything is tightened back up, problem still exists, it literally is printing a raised edge... I do not get it, it looks physically impossible, yet it's happening.... The only thing I can think of, and tell me if i'm crazy, is maybe the Extruder isn't extruding enough and it's stretching the filament and that is why it's popping up? 

Any other crazy ideas you guys can throw at me.... ?

Thanks
  Andrew

The little white blocks in the rear of the carriage are adjustable just don't tighten them up too much,

Yup, already looked at it, it's main job is to let the carriage move a little the other way, and not the way I have slop, the bushing actually has space and movement on the smooth shaft.... maybe I can adjust the white block on top to push back some more.... but not tonight....

Thanks
  Andrew

Still printing the same.

So, watching it print, it literally lifts the filament up and then back down again, it's not the Z axis, there is slop on the extruder's carriage now, the need to pull filament, acceleration etc appears to be causing the issue. 

I was going to go to the carriage replacement, my linear bearings are enroute, but when I have a moment, probably wednesday I'll rip the carriage apart and put it back together to see if I can get it to be steadier.

Thanks for all your help, anyone seen this before?

Andrew

I know elmoret will vouch for this, most people way over lube their printers.

I've run 700 prints on my SD3, roughly 1000 hours of printing, have not added any lubrication at all.