Still have the temp issues though. Redirected the fan at a 15-degree angle away from the machine. With a good steady extrusion going, I have to set the temp to 193 in order to maintain it at 180-181. Still sometimes it falls to 179/178.

The washer is there as a mechanical fuse. Is it possible you tried to extrude at too low of a temperature? At any rate, you can just grab a #8 washer, file down the edge, and reassemble. There's instructions in the kit version on this. I've run a single Filastruder over 400 hours with the washer without any slipping, and several other Filastruders over 200 hours.

You should tilt the fan away from the nozzle 10-15 degrees, and make sure the insulation is slid forward, flush with the nozzle. That should take care of your temperature problems.

Noted about the wiring - Rob's already revised his methods on this.

Also, the temp controller seems to need to be set to 190 in order to maintain a temp of 180. If you set it to 180 you get a result around 171. Temps hold steady as programmed no problem without any plastic moving through, but then they drop to these numbers when extruding. Dunno if this is what other folks are experiencing.

Also found that the fan's red wire was wrapped around one of the mounting pegs of the gearbox, which prevented me from pulling the fan out enough to be able to mount it properly. Fixed easily but keep an eye out for that on future builds.