My extruder wasnt calibrated properly.
Which meant I had my flow rate multiplier down to .8

Calibrated the extruder to draw exactly 100mm (which I had done 2 weeks ago, not sure if I should be checking that more often)
Tested my thin walls - .42 exactly
Printing a 25mm test cube at the moment and the infill is going down perfectly.

I could tell not enough plastic was coming out but with me thinking I had already calibrated the extruder I figured it was something else.

Flow multiplier is now .95

In hindsight even slic3r tells you that if your mulitplier is outside of .9 to 1.1 you need to check your e-steps...I shouldve listened!!

Thanks for your input guys, appreciated.

Im just adjusting a few things then im going to test .1 again with the new slic3r.

Ill be back :-)

I think the most important part when printing at .1mm is the first layer. I've calibrated my bed so that my nozzle is almost digging into the bed. It's probably too close and not recommended to print at .3 or .2, but I think I'm sticking with .1 for all my prints from now on, so I rather not bother printing .2 or .3mm anyway. Theoretically the nozzle should be exactly .1mm above the bed but I just do what any true technician/engineer does... eyeball it. (J/K, to all the real engineers and technicians out there.) Then from there, I adjust the flow-rate. I can't say what a good bed temperature is, but I've been using 85-100 and its been working so far.

From the picture you posted, it looks like the nozzle is much higher than how I've got mine set up. It may seem like the little beads of filament isn't enough but it actually is. It's coming out as beads because the plastic has nothing to stick to. Once that first layer is firmly planted the beads have the first layer to stick to and it smooths out like peanut butter from the nozzle and will no longer be beads.

I'm not sure about any of the bugs that the different softwares have either as I've only been using Slic3r 0.9.5 and Pronterface that Solidoodle has up on the website. I'm not smart enough (lazy) to learn new software.

Ill try to get pics of how my first layering is coming out when I print something else.

If i manually delete 2 of the values it prints fine.

now it wont print at all
when i hit print it turns off the extruder heater, even after I click it back on it continues to drop, i have to hit the emergency stop button to "break" the connection to the printer so i can regain manual control.

My start gcode is as follows

M190 S90 ; wait for bed temperature to be reached
M104 S192 ; set temperature
G21; set mm units
G28 ;home all axis
M104 S192,192,192 ; set extruder temp and start heating
G90; set absolute coordinates
G1 Z15 F300 ;move platform down 5mm
G1 X10 Y10 F3000 ;move to front left corner
M109 S192,192,192; wait for extruder temp to be reached
G1 Z0.3 F200 ;move platform close to nozzle
G92 E0; reset extrusion distance
G1 E5 ;extrude anchor
G90 ; use absolute coordinates
G21 ; set units to millimeters
G92 E0
M82 ; use absolute distances for extrusion
M106 S89
G1 F3600.000 E-1.50000

Any ideas?

I'm assuming 9.3 doesn't have this issue

Edit: my first layer height is .3, layer heights are .1

"infill flow for bottom layer was calculated incorrectly when layer height != first layer height"

Picture attached of the problem at hand.

Its a strange one.

Im running repetier .8 with slic3r 9.6

Perimeters are running at 60mm/s and infill is 100.

What am I missing about .1 thats so different to .3?

I cant for the life of me figure out what is making the infill change so much from one setting to another.

Any help would be appreciated, very frustrated.

Thanks guys