Downloading Prusaslicer now. This project just keeps getting worse and worse. Here are pics of my filament that is jamming:

Also, why is my filament still getting caught up in your Y? If the filament cannot reliably pass through the Y then this thing is useless. When I bought this your videos led me to believe that it would work, the filament would go through the Y and not get hung up half the time. I may have screwed up my cura settings but the Y is a part that should be able to reliably work when I feed in freshly cut filament. What do you do to get your filament to reliably pass through your Y? Or are you just hiding all the print failures?

It looks like cura is turning off the hotend just after the tool change: M117 3D Chameleon Tool T1 M83 ;relative extrusion mode M104 T0 S0 Why? How have I screwed this up?

Filament 1 loads, Filament 1 prints, filament 1 retracts, filament 2 loads (sometimes- sometimes it gets caught in the Y at the top where it enters, or at the bottom where it exits). then the hotend drops to 0. Why? I followed your instructions for setting up the 4 extruders. I used your website to generate the start/stop gcode and copied that into cura. I'm attaching my gcode if that will help. (Gcode will not upload for some reason) Also, why does my filament keep getting hung up inside your Y? I cut it at an angle. It seems to only be filament 2 that gets stuck. Do I have to open up the Y again and clean it out? Filament 1 has no string. I reduced the temp to 190.

I probably won't reassemble and test until much later. I have to get ready for tomorrow's classes.

I always use a razor blade to cut PTFE tube. I'm not sure how you want me to flare the PTFE, I didn't see your technique in your video. I just shoved one of the jaws of my filament cutters into the tube and rotated until the opening was flared.

I opened it up. I did not find any black filament inside. I cleaned out some dust (looked like some of the white filament that had been ground up in the extruder). I did notice that the ID of the PTFE tube is slightly less than that of the Y so I flared the end of the PTFE. That seemed to help. I haven't been able to get it hung up since then. I'll reassemble and retry a test print (I'm just printing four 20x20x0.3mm squares in four colors just to see if it can handle the filament changes.)

https://youtu.be/NqvvsBICYVQ

Maybe mine is defective. When I push a piece of filament through the passthrough, it gets hung up just before the bottom. I can work it through if I twist it while I push, but there is definitely something hanging it up down there. I'll make a video to show you.

It was not the black (you call blue) that was getting stuck, it was the red and white, both of which had been cut at 45 degree angles. I'll see if I can correct the stringing, but that won't help me when I have a freshly cut piece of filament. Both the red and white were getting hung up at the bottom of the Y nearest the extruder. not near your arrows. Do I need to open up the Y and clean it out? Can you either send me or make available the gcode you use for extruder 1 start and stop for your ender 5 setup? I'd like to compare it to what I'm using even if I fix the stringing and the gcode, the problem with fresh filamant will still remain. Why can't I get a piece of new cut filament to pass through your Y? Why isn't it manufactured with smoother internal geometry?

Does anyone other than you have this thing working? I have a brand new ender 5. The only modification I made was to buy a BMG clone (on your suggestion) and I installed it on top of the hotend in a direct drive configuration because I figured that would reduce the load/unload time. Perhaps I need to go back to an all stock setup - move the extruder back down to the side and reinstall the Bowden tube just prove that this thing doesn't work, even when I set it up just like yours in your Ender 5 videos. Even perfectly shaped ends are hanging up at the bottom of the Y nearest the extruder. There's something wrong with the design. The compression fittings on the Y are just loose in there. Would have been better if that thing was one solid piece with no internal lips for filament to get hung up on. I now regret having made this investment. I need to take a break from this so that I don't end up taking a sledge hammer to my printer. I'll try again in a few days. If I can't get this sorted soon, I'll just ship all this crap back to you for a refund. Multi colored prints are not worth this.

The black one wasn't the one jamming. It was the white and red.

see my video for where it jams. NMostly at the bottom of the Y near the extruder. I had thought this would take me 2-4 hours to set up. I think I'm up to 10 now.

Maybe I need to take the Y apart to see if there's anything in there blocking things?

I just pulled them all out to take a photo. Apparently the black had gone through the extruder at some point. The others looked as in the photos and wouldn't pass through the Y. The white is also cut correctly but you couldn't tell in the first photo so I took a separate photo of it.

These are all cut by me at a 45 degree angle. Nothing will load now.

I started out with a two color print- Failed. Now I can't even get the thing to load at the beginning of a print.

First print failed half way through due to a jam in the hotend. I've made some adjustments and will try again.

After adjusting the current, and having things still not work, I unplugged everything and physically forced the unit into position 4. It took quite a bit of effort. I then plugged it back and and it appears to be working correctly now. I'll try that test print again.