Have an odd issue. This is on my 1.0a running simplify and repetier .92. Printed direct usb at 4mm with a .048 (auto in the settings) extrusion width. In the picture below, you can see that one layer printed out further (both on the inside and outside) of the koozie. This does not show up in the preview of the slice. What could have caused this?

Try reprinting a .30. Your nozzle is a .40 and you never should print at the same size of the nozzle. You get over extrusion which is what that probably is. Also the system cannot regulate flow properly when you print at the nozzle diameter. With a .40 nozzle the max you should try to print at is .35. This is why after market hot ends have multiple sizes. If you want to print at .40 or above you would need to buy an after market and install a .50 which pretty much the largest you can get and that would let you print at .45 max.

What are your print speeds? You could be going too fast as well. I have found this printer has issues going higher than 50 on any move other than non-print moves.

What if somehow the Z axis skipped one layer, so the extruder actually passed twice at the same hight?

On a somewhat related note, sorry about what happened to the colts. Blame it on deflated footballs lawl

LOL! The irony is I seem to have a deflated layer with the build of this koozie.