Boz, that is CRAZY. I cannot believe how much plasfic that is. Good lord.

Edit: why was such an old thread revived? Weird

It was a pretty severe clog.  Burnt plastic had made its way out of the nozzle through the threaded areas.  My extruder was pretty much junk, so I got an E3D v5.  You could try using acetone on your brass nozzle to break up any clogs.  Just soak the nozzle in some acetone for a while, and then use a small needle/paperclip to get the gunk out of it.

I've attached a picture of what the clog looked like on mine.  It was pretty far gone at that point.

Could be a partial clog, but I'm also wondering about extruder temp.  Any chance the thermistor position changed?  Perhaps resulting in hotter prints?

I definitely suspected both of these as the culprit.  After installing a new extruder body, I can see how the thermistor changing position could be a problem.  I managed to overtighten and break my wooden piece on the old extruder, so I don't think it's too crazy to think that I messed up the placement.

The only other thing that says clog to me is the fact that my hotend can no longer operate at the low temperatures that it used to be able to handle (200°C).  If I just warm the bed up and hit the start button, the extruder will not warm up enough (even at the default 200°C) and will jam until it has had adequate time to warm up.  I've been bypassing this by preheating the hotend to around 205°C for a minute or so, and then running at around 205-210°C.  Running at 200°C is possible once the hotend has had time to heat up for a while, but it sounds like it causes unnecessary strain on the motor.  This could all be a byproduct of bad thermistor placement, but it also hints at a partial clog.

I will try to look at the placement this afternoon to check, and I will also try to run a single wall calibration print at my typical settings to see if it is still in spec.  I have previously calibrated the sizes and multipliers for each of my filaments, but it might have changed since I've gotten further into each roll.  The only reason I suspect this less is because I have attempted this with different colors and had similar results across the board.

I appreciate any help that anyone can offer me.  Thank you all.

Layer adhesion is pitiful, and the infill looks terrible most of the time.  I have more pictures if needed, but it just seems to be a mess all over.  I've been able to get some stellar prints from my machine, especially after adding a passively heated build chamber (that so far reaches around 105°F), but lately it has gone to junk with any color I throw at it.