Major fix, now destined for better 3D objects.

The issue I must have been fighting for a loooong time was due to the hobbed bolt in the extruder. I rectified it by trying to hob a new bolt but for the real grip I then took my dremmel tool with a carbide/diamond cutter, slightly thinner than the other cutters and cut grooves lengthwise through the bolt across the groove where the filament passes to give it better teeth. I used my drill press to hold the bolt so I could turn it as needed and use my dremmel in a vice that is used for milling and then drove the dremmel against the bolt to cut the grooves. The solid positioning helped not break the blade and give good grooves. I then tried making another square box and had solid sides this time. There were good thick walls so I may need to cut back on the amount of extrusion, but all the layers were solidly stuck together. The next problem to address is cooling all the sides. Cooling from the back of the object left the front rounded, so I will install another fan so that it is cooled there and the objects filament should solidify as it prints.
Now I should be able to concentrate on calibrating everything with consistent plastic flow.

Wholy holes Batman

I have learned that fan cooling is important so that the filament doesn't stay soft and deform after being laid. Above you can see uneven extrusion and 3 holes toward the bottom where you see the brighter patches. Above the dark patch there is another wide hole. I think that the thin spots (voids, holes, whatever) may be due to lack of extrusion rather than any other factor. I figure that since there are sections that have good extrusion, I have to imagine when I see the thin stretches, where there is a tiny thread of filament, that the filament was simply stretched from sufficient extrusion to sufficient extrusion, leaving the thin thread that I see. Hard to see that kind of detail in the picture, but you can see the uneven nature and the appearances of voids. So I hobbed a spare 8mm bolt I had and will see what happens now. I found a new technique slightly different from what I used, that is easier, so am including the link: http://www.youtube.com/watch?v=jSmhUWTSlZE. If I need to do it again I will use this method in that the washers give you someting to rest against for pressure rather than trying to hold the drill steady.