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Update: replaced the nozzle, heat block (heating element, sensor, PTFE) and fan duct. Did two new temp towers:
Left tower is 235 (top) to 260 (layers labeled 280-260 are all 260). Right is 220-240.
https://i.imgur.com/1MQkStE.jpg
https://i.imgur.com/HDWq19A.jpg
I definitely feel like 220 is the right temp for this.
In regards to the fan, I actually read a post saying PETG wants almost no fan, so I just left it on default but maybe I should try a fixed fan speed.
I’m pretty sure the popping noise was clogged PLA burning like crazy at 260c…
I've always understood petg to really like cooling but I print in an enclosure so YMMV, it's absolutely awful for bridges without cooling. Another thing to check would be extrusion multiplier and retraction. I get nozzle buildup if it's overextruding which leads to blobs and stringing, worth tuning that anyhow
Been doing a couple of test prints with 30-80% variable fan speed and it’s actually pretty good looking with almost no stringing.
I unfortunately don’t have an enclosure, else I would for sure try and higher fan speed. Ad a slight draft this morning and my calibration cube print popped off half way through.