Print quality now and before (Page 1 of 2)

Just a guess but it looks like inconsistent extrusion which could be your extruder (make sure it is still aligned and has enough tension), filament that's gone bad (try a roll you know 100% for certain is good), or your e3d is acting funny (make sure it has a fan on it and clean it out with acetone if you suspect it's slightly clogged).

Are you sure you put the e3d together correctly? I found out I messed up and had to rebuild mine. Make sure your nozzle isn't flush against the heater block; it needs to be fastened into the heatbrake, Also, you installed the PTFE tubing right?

Have you done a PID autotune? Maybe your temps are oscillating too low. I've been trying T-Glase the last few days and had issue extruding it below 240--it just so happens that my autotune values were a bit wacky and it was telling almost 10c too low. Just a thought since you mentioned PLA. Maybe try ABS and see if your results improve.

Are you using a fan when printing PLA?

What do your calibration cubes look like? Do they come out to the correct wall thickness?

PLA takes longer to cool than ABS, so it needs a constant airflow for optimal results. There are several printable fan mounts available on Thingiverse. http://www.thingiverse.com/search?q=sol … ;sa=Submit

A fan can also be useful for certain ABS prints...like at the top of the Tardis. Small, tight areas where the hotend hangs out in will prolong the cooling process and keep several layers half-molten until the heat moves far enough away for said layers to cool.

The holes look like you may be over extruding a bit. I had problems identical to that after updating RH recently, and many of my settings were changed. A good place to start is to check the filament diameter, check your nozzle size in RH (if you have a .4 nozzle, this setting will be 4.8 to allow expansion), then recalibrate your extruder.
These steps weren't a "silver bullet" for me, but it smashed 90% of my issues to where I am comfortable.

Interesting. I'll trying lowering my extrusion multiplier some more as soon as I get to my printer (which will be on Friday). Also I have nozzle size set to .4 right now. So I'll try playing with those a bit. I was actually thinking that the extrusion multiplier was set a bit too low because of those results.

He meant extrusion width, but setting the nozzle higher is a neat trick you can use to up the flow rate with some filaments, I.e. With T-glase I found upping the nozzle diameter to .5 had about the same effect as just upping the flow rate slider in RH.  In general you want all of this to be as accurate as possible because nozzle diameter and extrusion width not only controls flow, but the entire toolpath generation process as well. The slic3r documentation covers all of this pretty thoroughly.

Some folks like to use a 0.5 extrusion width with the 0.4 nozzle. It works for them fine but I just use 0.48 because slic3r is pretty good at figuring out what you wanted in your model. It's rare I have to think about extrusion space when modeling, even less so with better thin wall detection in the latest version of slic3r.

Do you see the gaps in the generated G-code or just in the printed part?

If an extrusion won't fit in the space it would knock other parts out of the way or behave otherwise unpredictably. Slic3r will do automatic extrusion width calculations and the documentation explains many of its automatic choices. But they never extrude UNDER the nozzle diameter for anything except support as its not really predictable what will happen precisely. This is my best understanding anyway.

I extrude support at 0.24 on a 0.4 nozzle for example and the support is hardly perfect, but in this case that's what we aim for; just enough to give a building surface without making removal difficult.

Not sure. They consider nozzleDiam * 1.05 to be the "safest": http://manual.slic3r.org/advanced/flow-math. Elmoret could probably provide some good insight on this I bet.

The e3d is a champ so maybe it just takes our abuse better??

Yeah, it isn't the best visual aid once zoomed in that close.  I was just wondering if there wasn't something mechanical causing issues.