I'm looking at a similar problem with a blocked hot end from PLA and soaking in acetone does help. Maybe it's just the PLA I'm using, but I can see white streams of dissolved plastic falling off the print head when it's in the acetone. Hasn't fixed my problem yet so YMMV, but it's work a try.by Opus - Printing
Slic3r puts the print head path on the actual circle of the hole, so the actual hole is smaller by the width of that extruded plastic in each direction. Skeinforge has a setting for automatically enlarging holes to compensate for this (though I've only looked through the mass of skeinforge controls and never actually used it!) Slic3r doesn't have an option for this (that I've found) The rest oby Opus - General Mendel Topics