D’Oh! Ok, this is getting ridiculous.
I cleaned up the previous mess (https://plus.google.com/u/0/+AlexWiebe/posts/DevnYpENVCY), made sure to turn on (ie: connect) my extra cooling fan and restarted the job.
Came down to find this disaster awaiting me.
So, clearly I need to:
Mondays. Ugh.
FWIW, I had an Ubis that seemed to start experiencing a lot of heat creep and when I replaced it, the problem went away. Not sure what happens over time (# of cycles?) that seems to affect the ceramic cartridge, but for sure something changed.
A good acid test is on a new one, you can touch the upper part of the barrel and not feel much heat, but on the one I tossed out…you couldn’t cause of the heat. I can also see yours is discolored like mine was.
@Tim_Sills I have been suspecting that. My setup is about 2 years old…
What’s with the heat sinks on the motor? If the motor is getting that hot, then something is likely not right with that.
Have you tried lowering the current to the extruder motor?
@Taylor_Landry The heat sinks were an early attempt to cool the entire extruder/hot end down. Normally the stepper barely gets above 35C. The heat management is all around keeping the heat-creep from the hot end down (thermally as well as physically).
I had the same issue with my printrbot, as a matter of fact I was not able to print at all without a huge fan next to it. Later I made this: https://www.tindie.com/products/FemtoCow/printrlight-light-and-extruder-fan-holder-for-printrbot-simple-2014-2/ It’a a 60mm fan holder that attaches under the extruder motor and blows air directly on the extruder. There are also LED lights on the bottom to illuminate the print. Works well now. Didn’t need to install heat sinks on the motor as I planned.
I don’t use my laser cut Simple much anymore, but I too at least have a 40mm fan on the front of the extruder to help keep things cool. Between that and a new Ubis hotend, it prints like new.
You could print the fan duct that they used to use on the old ubis 13 and shove it on the top section.
Send me your address and I’ll send another hotend- the v2 extruder is a lot better on tolerances if you still have a v1
Thumbs up 
nice gesture by @Brook_Drumm to help him out.
When I had the same issue I also got the newer hotend, absolutely no improvement.
You need to turndown the current and slow down. That was the fix for me.
I read somewhere that you do not want to do retracts with that type of hotend. Is that correct? Are retractions going on, Alex?
I’ve always printed with retraction and it didn’t seem to be a problem (don’t recall exact amount, but something like 2-3mm’ish).
If at at any you needed that much current, I would have to figure that you might have a partial jam or you were printing too quick or your temperature is too high to allow you to cool the barrel or some combination of those things.
Retraction (Prime/Suck in KISSlicer?) is an absolute to have a decent print. I have been using 3mm, but lately, in an effort to shave what few seconds off a print that I can, I’ve been trying 1.5mm.
I pretty sure the jamming is because:
a) the hotend is old and something is no longer in tolerance inside the top part.
b) I’m running hotter than normal and my cooling system failed.
@Brook_Drumm - I’m failing at G+. What’s the best way to contact you to send you information…
