Very Frustrated. First layer, every layer, problems

I was having problems with the auto level causing parts of the bed to print high while other parts were almost gouging the bed in strange places all over the bed. I though maybe my bed got warped so I switched back to the original print bed (was using the v2 bed) and continued having this issue. I had some PIE sheet sitting around and put that on to give it a go and had the same results. I contacted support and after a ton of troubleshooting, they decided to have me send it in for repair and inspection. They said that something in the gantry was cracked and that the yellow PIE sheet was throwing of the IR sensors. When I got it back, the gantry was mis-aligned badly enough that the x axis limit switch wasn't being hit and one of the belts had more than an inch of lose play in it. I fixed the gantry and belt tension, did the bed calibration, z-offset, and fine tune offset and started test printing using files that came on the Robo (filament clips, and a spiral bed level test). I am sharing a link to every picture and video I have taken from the beginning. Please tell me what you folks think. This has been going on for weeks and I am ready to give up and burn this thing!
Before sending off for repairs:
https://drive.google.com/drive/folders/1fV_lc7GxKHKSovDweyoi7wEYbxnI0Lps?usp=sharing

After getting back from repair:
https://drive.google.com/drive/folders/15AK5cRZCi_bYcbZYmKGuzsKFwBTolHuV?usp=sharing

 

I fixed the gantry and belt tension, did the bed calibration, z-offset, and fine tune offset ...

 

That's what the bed calibration is. It's the mechanical adjustments for the bed. You can do it manually or guided. I did guided. That takes the hot end to each of the 4 corners and you adjust the screws on the bottom of the bed so that there is a papers thickness between the bed and hot end at each of the four corners and check that the bed doesn't wobble when you press on it at the corners. I went through this several times to get it consistently leveled at each corner.

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I'm sure this would get me to a working state but.... I am still in warranty and expect Robo to fix this issue so that the printer works as advertised. I came to forum in hopes that we might find a fix for the problem. I'm also not sure that we are having a leveling problem. From what I can tell, the hotend is close enough to the bed and extrudes plastic just fine until I go to print something. If I just heat the hot end to 195c and extrude plastic, it works fine. I have the bed as mechanically level as I can get it. It is a papers thickness across the bed from the hotend to the bed.

 

I'll try turning off the leveling and see how it does, but I do expect Robo to fix it if it's an auto level issue. The blue tape and wire was before I sent to repair. It was lights. The blue tape on the bed was for holding down a piece of PIE. Robo said that PIE sheet was what was messing up the auto level, so they gave me a new bed, but it still doesn't work.

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Not a leveling issue. I have now been through the bed calibration and leveling wizards several times. There is a papers thickness between the hot end and the bed all the way around the bed. The bed doesn't wobble when the corners are pressed and when I turn off auto level its prints consistently level but doesn't extrude the plastic. I tried another larger model (a box and lid) and instead of the extruder gear turning at a slow consistent speed, it moves in one small jump waits a while then moves in one small jump again, over and over.
The extruder is not clogged. I can heat the extruder to 200C and using motor controls extrude 10 or 100 mm of plastic with out issue.

 

I've always seen that the nozzle should be a standard printer papers thickness above the bed when leveling. How high above the bed when leveling should it be? I've always done it this way.... 2 years printing.

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Sorry Geof, I think my frustration was showing. I didn't mean to seem abrasive to your suggestions. I haven't changed anything in EEprom yet, but I did change the first layer height from .2 to .3. It does extrude plastic with that change. So, I am one step closer to a good print. Now that I am extruding, I am having another issue. It seems the bed is not flat. The rear of the bed has a high spot about 80mm long (left to right) the entire front of the bed is high, and the center, and left center is low. If I try to adjust for these low areas then other areas are hitting the hot end.
Should I just get a borosilicate plate and put on the top of this bed? The bed I have looks like the original bed but it has a connector on it instead of the pogo pin pads.

 

Okay, good to know. I just turned back on the auto level and it seems to be doing better. Good enough I guess. I just don't understand what has changed. I was printing with no leveling, adhesion, or extrusion issues for like 8 months. Then all of the sudden, I can't print anything. The day before I started having all these problems I finished printing an articulated tablet holder for my surface pro, and it came out great, 1st layer to last layer.

 

I just finished my first print in like a month. This looks TERRIBLE!!
https://drive.google.com/drive/folders/1_aGRVRTVU80Y_GJtzZ8vfsD1e2Lo6kn1?usp=sharing