Heroic Printing Failures with the Thing-O-Matic and MK7

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Despite numerous attempts utilizing recommended settings, a large box print using TOM has failed 16+ times. The object's first layer often fails to stick to the HBP, causing warping, or the filament melts within the extruder feed gears, halting printing entirely. Despite adjusting various parameters and adding fans, there's been no improvement. Warping is mitigated through 'mouse ears,' multiple shells in Skeinforge, improved HBP leveling, precise z-stage height adjustment, and cleaning Kapton with acetone. The Mk7 design's short distance between the extruder nozzle and gear wheel may cause premature melting, affecting large surface area prints. Suggestions for next steps are appreciated. Using ReplicatorG0027 with updated firmware, 'Thingomatic w/ HBP and Stepstuder Mk7' settings, Gcode generation, and printing via SD Card resulted in failed attempts after a few layers. Post-print adjustments included Skeinforge setting tweaks, Kapton replacement, and HBP leveling. Yet, failure persisted across at least 16 tries.