Hi all. This is an update to this post. I don't know what else the community can do to help, but I figured I'd throw some more content up there and give something bored people to look at.
Since the last update on that post, I tried working on the printer in freezing temperatures (not really but it's cold in this house) with extremely precise practices on assembling the hot end (the same hot end I had haphazardly assembled dozens of times and printed with zero issues) and yielded zero progress. Today, I tried a brand new PTFE lined heat break, along with a brand new Capricorn Bowden tube (I already had one but I needed more tubing for the heat break). Clogging in the same exact way in roughly the same amount of time as every other attempt. It's as if I've not tried anything, literally nothing is effecting the results.
I considered ordering a fancy micro-swiss or ed3 hot end, but at this point, including the stock hardware, I've gone through 6 heat breaks, 3 heat blocks, a half dozen nozzles and a foot of Bowden tubing, none of which did anything to fix my problem (or even make it worse). I would look to the extruder, but I outlined in the previous post the testing I did to rule that out (able to run >1m of filament at high and low speeds through the Bowden tube).
I'm at the end of my wits. Perfectly good printer cranking out multiple high detail prints a day, now completely useless over something so stupid as clogging. Where the hell else can I look? Could it possibly be some sort of software/firmware issue, where Klipper isn't sending or receiving the right commands or something? I know my slicer settings are at least good enough because I've tried both prints that have completed dozens of times as well as new prints with drastically reduced retraction. Do steppers need to be tuned over time? I don't think it makes sense that after a year it'd suddenly become so uncalibrated it's unusable, and when I tried calibrating it before I was just unknowingly calibrating against mild clogs, but I don't know where else to look.
Any suspicion of the heat cartridge failing? Might work long enough for a pid tune but not be able to maintain temp? I'd also look I to the extruder, once you put the nozzle on its working much harder.
I suspected a faulty cartridge, but that would reflect on the temp chart no? Unless the thermistor was somehow failing perfectly to match the change.
I think I do have to look to the extruder. I'm nervous about it because I don't know anything about how to maintain or diagnose them, but I guess there's a time to learn everything.