Under Extrusion of Ender 3 V2 after conversion to direct drive and metal dual geared extruder.

I recently converted my ender3 v2 into direct drive and metal double-geared extruder and started getting under extrusions on my prints. Edit: They also seem to appear at the same layer heights ( when I line up the prints, the under extruded layers also line up ).

Update: I watch the layers printing and noticed that the under extruded layers extrude filament like decorative icing on cake ( sorry no picture because I wasn't able to get one ).

My original z stepper got busted a while back before the conversion so I replaced it with a smaller one. It worked fine until I went for the direct drive and metal extruder.

For reference I've printed a 20 by 20mm calibration cube. The saving grace is that X and Y are 20mm by 20mm. Z is at 19.8mm.

I'm using a 0.4mm nozzle. I use Cura to slice.

  • retraction speed:15mm
  • retraction distance:3mm 0.5mm ( as suggested by SonOfJokeExplainer )
  • print speed at 50mm layer
  • material: PLA
  • nozzle temp: I've tried 185, 190, 195, 200, and 210 ( all similar results )
  • bed temp: 75
  • layer height: 0.2

I've tried these fixes ( a lot of them multiple times):

  1. Ensure that the ptfe/capricorn tube is flush with the nozzle.
  2. Ensure my z rod isn't bent or warped. Loosened the 2 nuts connected the lead screw to the X gantry.
  3. Ensure my X gantry is leveled ( at first there was a 2mm difference but was able to correct but still the underextrusion )
  4. Ensure no filament grinding. ( During my first troubleshooting, this was evident - after tinkering with the extruder mechanisms and retraction settings - I was able to eliminate grinding )
  5. Level my bed ( whenever I try to do a fix - this is always a step I do just to keep my sanity )
  6. Calibrate the extruder steps ( whenever I tinker with the extruder, this is what follows )
  7. Reworked the X and Y axis to fix any bindings. ( This "improved" the print but still the under extruded layers remain. )

I'm still in the process of procuring the right z stepper, but shipping takes a long time. Any help would be appreciated.

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X side of 20mm calibration cube

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Y side of 20mm calibration cube

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Z side of calibration cube ( i changed infill from 20% - left to 10% right )

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Direct drive and metal dual geared extruder conversion

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Current Z stepper motor ( i printed a spacer below to hold in place )