here is what I did. I forgot to take some step pics but i'll show you what I got and explain the rest.
THIS MOD IS NOT FOR EVERYONE!!!!! I HAVE CNC MILLS AND LATHES AT MY DISPOSAL , BUT THIS COULD BE DONE WITH SIMPLER TOOLS.
ok first disassembled the hotend. the plastic heatsink will easially separate with a vice and 13mm wrench.
then I ran a drill through the entire brass piece just to clean it all out.
then I placed the hotend in the lathe and turned the tip flat. I was going to get rid of the tip all together and face it all the way to the square block but after measuring everything I decided to stop once I got enough flat to mill it and thread it.
After that I put it into the mill and this is where I got lucky with the face I did on the lathe. there was enough of the round part to touch off center. I did a quick program with a 1/8" flat endmill and milled a 5mm diameter hole to a depth of .318". then by hand tapped it to m6x1.0.
when I tapped the threads it did break through into the area that the heater goes. once I got the nozzle in I had to run a drill through the heater hole to allow the heater to clear. So at this point I am not sure if I have a reusable hotend or if I just extended the life of it one time for $15 and 30 mins of my life playing.
Ill post more as I get results. I am printing a single extruder to swap everything over. I did notice that it is slightly longer with the screw in nozzle so the touch bl will need adjusting
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