It finally dawned on me. I've been thinking the bend in the blade should be in the same plane as the arc created to lay down mud. A comment somewhere about an S bend had me comp...
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I'll try the bend. Yes, I bought a new pump. I didn't want to take the chance on a used one.
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http://www.drywalltalk.com/f7/hairline-crack-problems-377/ This is the discussion that saved my ass. Fergafinish has it right.
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