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[img]http://i.imgur.com/RmgzDrfl.jpg[/img]

Image says it best. Suggestions?

This happened to me too. Just shave the leg down a bit that the red tensioner is screwed to, allowing it to sit more square.

Have you tried to pull the hobbed gear out further to align the knurled section evenly under the bearing?

KAS wrote:Have you tried to pull the hobbed gear out further to align the knurled section evenly under the bearing?

^This^

Try to line up the groove of your gear with the flat edge of the bearing by loosening the grub screw and sliding it down the shaft. That should help LOADS.

The groove really should be lined up with where the filament exits the extruder, or you'll run into issues with the filament binding at the exit, which will lead to things like filament being eaten by the extruder.

What I usually do is cut off a length on filament, and before I tighten the gear onto the stepper shaft I run the filament backwards and forwards a couple of times to line the hobbed section up with the exit, i then tighten the setscrew with the filament still in the extruder.

I think what he is showing is the the filament is slipping behind the tensioner.

Because the hobbed gear groove isn't lined up with the tensioner bearing.

They need to be lined up on center
[img]http://i.imgur.com/ehKSAGe.jpg[/img]

Indeed

JFettig wrote:Because the hobbed gear groove isn't lined up with the tensioner bearing.

They need to be lined up on center
[img]http://i.imgur.com/ehKSAGe.jpg[/img]

Did you make that adapter plate for the geared stepper?

Yessir and I can make more

I briefly mentioned this issue in this post; http://forum.seemecnc.com/viewtopic.php ... 4&start=25

It may not be the same scenario, but looks like it is. Check your stepper temperature that may make the problem worse. If you take off the clear cover when in motion, you'll see the red tab moving out as it's retracting. I think that cover is supposed to hold it, but if your stepper is hot, it can make it weak or crack in my case. I just took off the cover and zip tied it and never had the problem again. A better solution would be to design or print something that attaches to the red tab via surrounding screw locating holes, where you're fixating or pushing against the red tab ever so lightly, but firm.

Just for anyone looking to use a geared stepper with the ezstruder, you can avoid having to make or buy an adapter plate by using the following motor: http://www.robotdigg.com/product/425/Fl ... mm+Stepper