This is just a quick remix of the TS-80 case I made a while back. This one is larger though, so a USB cable can be stored in it. It is now posted on Thingiverse (but not yet tested):
So I swapped the worn stock arm on my extruder with another of the same design (which fixed the looseness of the non-driven gear), but that did not fix the underextrusion. I also replaced the bowden tube and coupler which helped a bit. And now I have swapped the nozzle with this one from Amazon, and from the looks of it, it is a pretty nice looking nozzle, however the first print was not perfect (had some boogers) - but I am still testing it. I am hopeful that this new nozzle will work for my printer, since it looks very well made (almost appears polished inside which is not found on cheap packs of MK8 nozzles typically). I have some longer prints lined up which should be a better test.
After months of great service, the CR10S Pro now needs some help. It was poorly extruding, so I tried swapping everything out from the nozzle to the bowden (and couplers), checking extruder steps, tearing down and rebuilding the hot end and checking the filament diameter, and then found this:
The arm is clearly worn from the gear rubbing against it. I'm not 100% sure that this alone is the problem but it certainly does not look great, and I need to fix it. Update - it looks like it is not 100% of the problem, I was able to reduce the underextrusion quite a bit by removing and re-installing the bowden tube again (suspect that the tube was not fully installed in the extruder. The problem with the extruder arm however will need to be fixed or replaced.
But there is a fix, provided by TinyMachines (https://tinymachines3d.com/products/creality-10s-pro-extruder-lever-exchange-program). They will mill out the lever and provide some bronze washers for $12.50 (plus shipping). It is cheaper to get a new dual gear extruder from Amazon, but it looks like many of those will probably have the same trouble in time, so this is a better fix if the idea is to keep it stock. There are certainly better options for direct drive extruders, but right now I just want it working again and don't have the time to spend installing a Bondtech of Titan (which require firmware and vref changes). Not sure what the turnaround time is on it though.
And here's a great video which explains the fix from Liqui-Dirt 3D.
Update #1 (2/4/2020): I swapped the arm of the extruder with another which was not worn (bought a spare which is nearly identical and has the same dimensions on the arm). It did not help, so now I am leaning to the nozzle since I recently swapped to a cheaper set, and although I swapped it, it was with another nozzle from the same batch. The problem did not immediately start with the nozzles though so I am still not sure. So next up I am gonna try a better nozzle and see if the problem continues.
The extruder arm will still get replaced once I get the fixed one from Tinymachines since I can see definite wear on mine (and the gear can now move a bit over a mm up and down in the arm due to the problem), but the worn arm does not seem to be the problem in this case.
My mission is to lower the collective IQ of teh Internets one post at a time.