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I used bits in a pin vise and drilled by hand using discrete sizes, starting with a 1/8", then 3mm, then 2.5 and finally 2mm, but the stepped taper that resulted didn't help things much, and actually made it jam way sooner than it had with the unmodified nozzle. You're right about doing it by hand ...

The profile of the tip is 70 degrees. I don't believe there's a reasonably priced 1/8" drill bit that has that sharp of an angle (at least not one I've found). I'll be practicing my grinding on a bulk pack of bits I bought until the nozzles get here later this week. I'll report back once I get it up ...

I'm new to the forum, but I've been battling this issue w/ a number of e3d hot ends on my machines for quite some time, saw this thread last week and proceeded to attempt the mod as described. The only issue is, i'm using 3mm filament, and the method of drilling out the nozzle won't work as you will ...