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@John How tight is your anti-backlash nut (this one that goes into the middle of the bottom of the middle assembly http://www.vicious1.com/wp-content/uploads/2015/07/IMG_20160527_12563801.jpg )? Is that what you’re talking about when you say “I’ve had to leave the nut assembly fairly loose”?
My Z buzz stopped after I loosened it. At that point I had tried the firmware flash, but I hadn’t yet tried lubing the rod and I never adjusted the Z voltage.