I decided I was going to purchase a new hot end as a last effort, if it didn't work I would then indeed cannibalize my machine. Instead of choosing some random supplier and risking getting some garbage extruder like I did with my first replacement, I decided to go to my original supplier makerfarm.
I purchased a new Hexagon hot end, a new hobbed bolt, and a new Greg's Accessible Extruder (printed parts only since I figured my previous bearings and everything were still good). I also purchased the extruder so that I knew that the gears would mesh right since mine were very worn. I put my full trust MakerFarm
Hot end and fan. It was stressed to me how important it was to cool the body of the hotend during the print. Do not skip using a fan that blows on the body! Not on the tip where the plastic comes out, just the body. (Now makes me wonder if that was part of the problem with my second hotend?) The other thing I love about this new hotend is that little rubber booty that holds in the thermister and insulates the tip of the extruder. Very nice upgrade!
Extruder . Looking good :)
I then went into calibration mode (haha seems there is never ending tweaking with these machines) I followed the steps here for calibration. Everything worked like a charm. Now time to test the machine out. All of this update actually happened in mid November but I had to hold off for specific reason :) More revealed in the next post.