who is getting 300g per hour?

ABS can be very different. I had low output when temp was too low for the given batch of plastic. Try rising the temp +5-10 C and see if it makes any difference. If filament becomes too thin, reduce the pulling of filament (make the loop smaller).

So what is the official output expected in grams per hour and filament cm/in per minute.

I've reread the 1/4 sticking out instruction which I missed as I put the collar on before reading that.
It looks like I have the distance between the two flanges too small by over 1/8 inch, so I'll rearrange
using the original layout (flanges on each side of the wood) and with the original black spacers.
Assume that the too close auger does not have enough space in the void between auger end and nozzle
inside surface to build up sufficient pressure.

If the distance betwen flanges is an obvious indicator of correct auger end, could this be stated as a correctness check in the instructions.

Does the screwing tightness of putting the pipe on the flange, collar on and nozzle make for a range of space in the extruder which it looks like is crucial to flow rate? could there be variation In the dimensions due to where and how much the pipe threading was cut.  Perhaps an internal distance from the end of the auger bit to the nozzle outside end could help for extruders doing only 8cm per min.

Regards the motor, it operates about 6 rpm right? The torque on the motor had a wide range to very hard, bent the pipe a bit. I'm going to have to put a few washers on a side to get the pipe vertical.
I have put high temp epoxy in the gaps between the five commutators in the armature, will get a nice smooth surface as viewed under a 15x magnifier. It will be interesting to hear what happens. I'm hoping the gear noise is a resonator of the vibrations caused by the DC commutator gaps in the paper linked.

100g per hour will be nice, I got 370 in 21 hours, 17g per hour. Beautiful filament.

I do very much appreciate and value your advice.
I am university educated  and had a 20 year (short career) in IT research (no phD but basic computer science govt funded applied computer science). I say this in hope of gaining a bit more respect from you.

Regards the motor, Have you tired what I am doing? I probably am wrong, but why not try?
The paper linked implies something is there. Your point is noted of course, I will confirm it soon.
The noise is a major issue, given all day operation, its closeness, and the small amount of power < 60watts, this is a lightbulb.

Yes I stuffed up the flange geometry and would have saved my time and yours, sorry.

Still there is no actual internal end of auger to end of nozzle  dimension and its tolerance and subsequent effect on flow rate.
Remember there are three pipe threading tasks/ nozzle tightening to get within 1/8 inch tolerance of whatever this internal
vital dimension is. If people are having flow problems this dimension could be a quick check.

I have always tried to wait alt least 10  minutes at reported working temperature. I am experimenting with
different plastic mixtures so I am voiding any implied guarantees.  I have a setup  where I can unbolt the
motor and put a wrench onto the auger to feel the current torque, whilst the heater is still on. At times the
torque was guite large, yet the last full abs + 32:1 masterpatch was light to the pull. Still the motor grinded away
without the gears spitting teeth in all these cases.

Hi,

The new barrel replacement that I received did not look like, on the inside , the typical black iron
piipe that you get at the hardware store. It looked like the inside had been sand blasted with rough grit.
That would be an excellent way to really rough up the insde of the barrel evenly if you have access to a sand blaster.
I was actually thinking of blasting the inside of my barrel sometime with rough grit to see if it would increase
my extrusion rate.

No, you found me saying that a couple users (out of thousands) with heavily modified Filastruders (not stock) and 3mm diameter filament (easier to extrude) report (but may be confused/dishonest) 1kg in 3 hours.

That is not me saying that the typical rate is 300g/hr. I have never said that.

No one has attempted this. It may make things better, or may make things worse. Have you tried the things the very experienced users in this thread recommended? (run natural ABS without colorant, increase temperature)? How about the things very experienced users have recommended in other threads? (clean the barrel)

People have recommended cleaning the barrel (some folks use a blowtorch) and running natural ABS to eliminate the masterbatch as a variable. Have you done that? Have you at least tried a run of natural ABS without colorant?

There have been exactly 9, including you. That is not a "lot", it is less than 0.5%!

elmoret (v1.3) - Problem happened after ~1500 hours of use, 95% MG94, 3% other ABS, 1% PLA, 1% ABS+black or green colorant. Prior to the clog, nothing my MG94 had been run for several hundred hours. Disassembled, removed plastic plug, reassembled. Problem has not resurfaced for ~200 hours since, extruding MG94 at temperatures from 180 to 190C. In the link, I detailed everything I observed - including the fact that after the barrel cooled, I could rotate the auger with a wrench - indicating the plastic was not even touching the walls of the barrel anymore. The jam occurred after heating up from cold - not after running for a period of time.
IanJohnson (v1.0) - problem happened after running Asaclean. Replaced barrel, problem did not resurface.
insta (v1.0) - problem happened after ~100 hours (5kg). Ran nylon pellets which seem to have pushed clog out.
digitydogs (v1.3?) Ran MG94 ABS and PLA for 200-500 hours, several jam/clean cycles to no avail. Two machines exhibit this behavior, two do not. One of the two exhibiting the jam ran GITD filament right before the jam, one of the machines that does not exhibit this behavior has run 50lbs of GITD filament.
kitcarguy (?) Ran GITD filament in the first few hours of use, jam occurred. Disassembled and cleaned twice, problem went away.
kszwab Improper assembly, problems stopped after correct assembly.
Ggalisky (v1.5)- Experienced 1-4"/min with MG94 and GP35 at 1.75mm diameter. Went up to 16"/min after clearing the clog, no issues since.
ericpaulbishop (v1.4) Experienced "dramatic slowdown", found that higher temperatures triggered it sooner, found that wrapping the barrel helped.

So then:
Myself, Ian: Cleaned barrel, no further issues.
insta - Purged with natural Nylon, no further issues.
digitydogs - Barrel replaced, no further issues. Also of noted that he has processed over 2000lbs of material.
kitcarguy - ran glow in the dark masterbatch, known to cause issues. Cleaned barrel, no further issues.
kszwab - improper assembly, no further issues after proper assembly.
Ggalisky - got a random plug of plastic stuck to the auger, cleared it, no issues since.
ericpaulbishop - experienced slowdowns, found wrapping barrel resolved it.

Yes.

What cases?

I do do customer surveys, randomly. Feedback is almsot universally positive. If I hear of someone having trouble, I try to help them. I'm trying to help you - I still haven't heard a complete list of the polymers and master batches you've tried to extrude. I also don't have an answer to the questions posed above. I'll repeat them here for clarity:

It is hard to troubleshoot and help users without a full set of information, but I'm trying.

Folks tend to post to forums when they have problems/questions, not when everything's going swimmingly. For example I love my Macbook Pro, but I don't post to forums about it. On the other hand I can find thousands of folks posting about the problems they're having with their Macbook Pro. Does that mean the Macbook Pro is bad? Of course not, they sell hundreds of thousands of the thing so a few folks reporting issues are a very small percentage of the population. Often times, those issues are self inflicted - water damage, downloading malware, not updating software, etc. Anyway:

There's tons of folks enjoying their Filastruder. Some examples:

http://hackaday.com/2014/11/24/custom-f … lastruder/
https://www.youtube.com/watch?v=TMi4F-RXKLI
http://www.filastruder.com/pages/testimonials
http://www.soliforum.com/topic/10862/pcabs/
http://www.soliforum.com/topic/10731/abs-3mm-extrusion/
http://forum.seemecnc.com/viewtopic.php?f=80&t=6285
http://ggabrielson17.blogspot.com/2014/ … er-is.html
http://www.soliforum.com/post/97499/#p97499
http://www.soliforum.com/post/88187/#p88187
http://www.soliforum.com/post/46570/#p46570
http://www.soliforum.com/post/56808/#p56808

That's just some off the top of my head.

Polymer runs so far, (no more that 30 hours).

1/2 ABS and HDPE (shredded milkbottles on a large throated hopper, got about 5inch /min Filament brittle, snaps on bending.

ABS and about 1/3 recycled ABS print scraps. Go a dark brown filament,  Flow eventually stopped.

ABS and yellow/red masterpatch  from OSP in 1:32 weighed ratio. Beautiful filament with prober bendability, but 17g/hour.

And this quick flow 130g in under 20 minutes, ABS with 1:10 ratio diy masterpatch (too weak).

Like I said above: If the stall protection board is configured correctly, the motor cannot generate enough torque to bend the barrel. If the barrel is bent it is possible that the bend cause the inner surface to be polished or otherwise altered. Running with a bent barrel is bad news. How did it get bent? Also you can't really straighten the barrel with washers.

What about the initial run of the included ABS that was in the instructions? Did you skip that? Why?

No.

The motor should not be able to "strain" more, it has a current limiting board which limits torque. You should be in current limiting at torques only 20-40% higher than normal running torque.

Generally no, depending on your spool diameter. You can get a faster gear motor for it, though.

I think I bent the barrel when doing the run with 1/3 recycled plastic. Likely I let the temp drop too low when stop starting. I just aligned the barrel onto the motor with the washers.
The auger is loose enough fit in the barrel. Does the cut out of the barrel weaken it so it susceptible to impatient restarting? Could a piece of pipe be welded around this port?