Cooking with ABS...

Your assumption is probably correct and if you are using ABS then the only thing you can do is take the head apart and tear it down to just the metal and soak it in Acetone over night. If it was PLA then the best you can do is again tear it down to metal and burn it out with a torch. You really want to avoid a drill as it can damage the neck and also leave metal debris in the hotend which could cause an additional clog.

Welcome to 3D printing and learning what not to do by doing...

Mark

You might want to try a beauty supply. They sell acetone nail polish remover.
I goggled and got this.
https://www.sallybeauty.co.uk/nails/gel … S1416.html

Dale

i wasn't so lucky last week. I had to buy a Gallon. and that will last me 5 years if it doesn't evaporate.
Both big box stores were out of the quarts.

In the UK, things are much stricter, you can't just order chemicals, some chemicals can only be sold to established businesses or trades. Because I live in a multi-story building, there was a few changes to the tenancy agreements, like wording was altered to be quite ambiguous because of Grenfell Tower, anything of fire risk, you are not allowed to keep in your residence and that includes eBikes.

Certain trades have certain chemicals, if I was in to fibreglass and had my own fibre glass moulding shop, I'd be just fin getting hold of the stuff. The general public as a whole, even if you have a hobby or past time you enjoy, there is often some by law you're breaking, not allowed to do something because of certain dangers, my last landlors inspection, the agent was fraking out because she saw two extension leads being used out of a double socket and had the local fire department come around and inspedt for a fire hazzard. So you see,  I have got to be careful.

When I look on the US continent, I can get an IBC of the stuff for next to bugger all $$$ wise.

Only place I have found that looks like lab quality stuff is via Amazon in the UK and it is 500ml and looks to be £6 + £4.47 delivery as this requires hazardous chemicals handling. I don't like giving Amazon my money, to me, they are no different than ebay and walmart. Very handy but destroying ma & pa shops.

Yeah, I still got plenty of bullets to chew on already... Any ideas on how to soften them up a bit, bloody hard to chew...

Yes I know and the acetone I have seen in the shops is Gel type, which seems to be more popular and I have had a few weird looks when I say I have an FDM and need acetone for it, then explain why pure acetone is needed.

I found a source on amazon, it looks like I will have no option other than to try nail polish gel, I am wondering if the gel could be broken down by blasting it in the microwave, see if melting it will make it easier to work with.

please do not try microwaving it.. definitely NOT a good idea.

Any store that sells nail polish, should have nail polish remover.. look around, I am sure you can probably find something.

at this point, I would also suggest purchasing a spare nozzle or two for backup.

Well I thought that it being a gel, like most things that are, melt when heated and its not like I can apply an open flame (blow torch) to it so a non incandescent source of heating.

Maybe if I were to part boil a bottle of gel in its container at the boiling point of acetone, hope that the seperation allows for decanting of the raw acetone.

The other option is to distil nail polish.

Seriously - do not heat the stuff directly!

if you want to try to warm it, heat some water - take the hot water OFF the stove, place the bottle of gel polish remover in the hot water. And even then I would use a lot of caution..

or maybe take a look at the links Tin Falcon was so kind to share..

the ones here who have uses acetone for smoothing have done so outside in an open well ventilated area.
if a fire accures no chance of damage to property.
the problem with heating acetone in an enclosed area is  vapors can accumulate and then if ignited cause a flash fire.
that is why chemical plants have electrical classified motors switches lighting etc. require employees to wear nomex clothing and have good ventilation. 
I would not even thinking of working  with heating the stuff in a house or apartment.

or it could have been a chip from manufacturing your heat block. For year the chines have had a rep  of not cleaning  parts.
Guess it does not matter problem solved.