Happy to swap out the barrel and auger - just send an email through the Filastruder website.

Is that 4"/min on 1.75mm filament?

Email sent!  Thanks so much!

Yes, this is 1.75mm.

Is that 4"/min on 1.75mm filament?

Free float until the first time plastic is run through the machine. Is that not the case?

No, that is what I have.  It free floated a bit, but now it's solid.

Did you put the nozzle back on and try extruding after clearing the melted plastic? Did you verify that the nozzle is clear (soak in acetone to confirm)?

If yes to both, the only thing I can think of is there's an oddity to the auger or barrel. I can replace them if you'd like.

Thanks for the quick reply!
Yes...to both.  The nozzle had just been cleaned and the screen replaced.

I really wish I had an answer to all this (because the filament I had been making was working perfectly), but if you would like to try a new barrel and auger, I have no problems with that.

One question....when I assemble the nylon collar and then the thrust bearing, should they be "squished" between the two flanges, or should the entire assembly "free float" about 3-5mm?  I thought it was supposed to float so as pressure is built up, it pushed the assembly back into the flange that's on the inside, by the motor.

If yes to both, the only thing I can think of is there's an oddity to the auger or barrel. I can replace them if you'd like.

I did note that there was melted plastic further up the shaft than I expected.  After removing it, the pellets began to flow freely down the shaft.  I checked my temp with a separate temperature gauge, and it's correct.

Help!  Extrusion rate = 0 now.

I just use light oil, but it shouldn't matter. 1200 hours on the original bearing.

Did you lubricate the thrust bearing?
What material? (Resin ID?)
What temperature?

Yes, I lubricate the thrust bearing.  Do you recommend a specific brand of lubricant?
I have been using ABS plastic from Open Source Printing (which is now closed) and another brand of ABS with the same results.  All brands that I have used are MG94.
While I have tested ranges from 180-192, my current setup is for 188. 

Generally, my filament is just fine....it just takes FOREVER to make.  Like I said earlier, in 48 hours of making filament, I don't even fill a single spool.

Also, do you have any recommendations on how much spacing there should be inside the coupling?  I have the auger sticking 1/4" out from the barrel, but then we screw on the coupling and then the nozzle.  That still leaves a lot of space and I'm wondering if that's the issue.

1.  Crazy slow extrusion from the day I originally built it.  It takes over 2 days to fill one spool of filament.  I've readjusted the auger, but I can't seem to get decent extrusion rates.

2.  The bearing completely fell apart and parts of the metal had been worn away.  I'm guessing something isn't setup correctly.

So, with those two items, I'm not sure if my assembly is correct or????  Pics are below that show the auger 1/4" from end of the tube.  It also shows how I have the screws assembled on the flange and filastruder enclosure.  Documentation is a bit thin in regards to this setup with the enclosure and the parts that I was provided.
Also, I'm not sure how far I should screw the coupling and nozzle on.  I'm guessing that my crazy slow extrusion is due to an incorrect spacing somewhere in this area. 

Any help would be appreciated!