This large chunk of abs slowly extruded out of the back of the extruder where I couldn't see it. I hate to think how long its been leaking.
I think the ptfe piece got too hot and distorted and let goo leak out around its threads.
This means the last few tests are flawed since the abs was at least partially going that way.
Tho this does explain why the past few tests were janky.
Sigh...now to fix it....feh...perhaps find some ptfe and drill the right sized hole. Doesn't really need to be a tube. Just as long as it fits in the space.