You could move to an E3Dv6, E3D Lite6, pair of either of those, Cyclops, or Chimera... but you'd have to come up with your own mounting solution.

Airwolf's mounting solution was to 3D print their own polycarbonate case that snaps onto the guide rod bearings. I'm sure something similar would work... although I will probably need guidance from some certain other more experienced individuals

IronMan wrote:

B - how do you print ABS / PLA combinations which would require 2 separate heat settings?

That was exactly what I asked them after I bought the printer and realized the nozzles weren't separately controlled. Their solution is to use "compatible materials"

Wow...and last I knew, the TPU / ABS combination they used in their demo video would require around 180/230C respectively...I could be wrong as I never ran TPU, but the EcoFlex I run needs about 180 as well.

I was wanting to go with something non-proprietary because their replacement parts are really expensive. A single replacement .5mm nozzle is $33.

You could move to an E3Dv6, E3D Lite6, pair of either of those, Cyclops, or Chimera... but you'd have to come up with your own mounting solution.

Based on your past mods, I'd say that won't be a problem for you.

Those types of heaters are very old out dated tech from before the 12 and 24 volt cartridges where introduced.

B - how do you print ABS / PLA combinations which would require 2 separate heat settings?

That was exactly what I asked them after I bought the printer and realized the nozzles weren't separately controlled. Their solution is to use "compatible materials"

Are they really only using one 24w heater for that huge block? Yikes.

I didn't notice that...one heater for both nozzles?
A - not enough power...
B - how do you print ABS / PLA combinations which would require 2 separate heat settings?

Yea, and it's a dual extruder at that - so a single heater for both.
Those are some good ideas. I'll go ahead and place an order for a heater and try to insulate it after I put it in.

Are they really only using one 24w heater for that huge block? Yikes.

You should be fine drilling and tapping a set screw and using a 40w heater. You could also try wrapping the heater block in high temperature insulation.

IronMan wrote:

It slides easily without loosening any type of screw?  If it is not tight, you could be losing some heat transfer...

There's not a screw to be loosened. When I say "fairly easy" i mean applying about a pound of force with a blunt tool. Do you think that could be part of my problem? Seems like a design problem to me.

Sounds OK as long as it was not loosey-goosey(tech term).  I would have designed it with a hard screw-type clamping feature...

It slides easily without loosening any type of screw?  If it is not tight, you could be losing some heat transfer...

There's not a screw to be loosened. When I say "fairly easy" i mean applying about a pound of force with a blunt tool. Do you think that could be part of my problem? Seems like a design problem to me.

heartless wrote:

The green thing in the circled area is the heater cartridge and should be removable from that block so it can be changed/upgraded fairly easily

Ahhhhh, okay, that part does slide faily easy and it is 6mm.

It slides easily without loosening any type of screw?  If it is not tight, you could be losing some heat transfer...

"The HD2x comes standard with Airwolf’s new proprietary JR2x dual high temperature hot end"

One option would be to adapt to a Chimera from Filastruder:

http://www.filastruder.com/products/chimera-cyclops

but that would entail a custom mount of your own design and most likely updating your nozzle offset distance.

If your hot ends are functioning I would stick with trying to replace the cartridge heaters to 40W if they the 6mm diameter as elmoret suggested.

EDIT: A little late with this..

The green thing in the circled area is the heater cartridge and should be removable from that block so it can be changed/upgraded fairly easily

Ahhhhh, okay, that part does slide faily easy and it is 6mm.

The green thing in the circled area is the heater cartridge and should be removable from that block so it can be changed/upgraded fairly easily