I read your article and some of the problems you are having with your sprays getting clogged. I hate bragging but I have not had a spray clog on me since I started my system 11 months ago.
I feel for you that you are going through so much time dealing with your system.
So here is the main problem you are having. One the nutrients you are using are the main problem and the preasure of the pump is the second. This is a guess of coarse since I do not have my hands on your system, but it seems to be the most logical. I have details of what I am doing at http://myaeroponics.com where I share my DIY system.
But I use BMO nutrients found on ebay, no clogging and a 1000gph aquairium pump. Each 20 gallon tub has four sprays that spray all over inside. I have more problems with leaks from the lid because of the volume. But my everyday schedule is keeping the reservoir full and the PPM nUtrient level at 250.
Mar 21, 2010 Rating
PEX tube instead of PVC by: ProZachJ
I have found that using PEX tubing inside my Rail systems with 1/16 holes is much better than using pvc. The quick disconnect fittings that are available for PEX tubing make dealing with the spray lines much easier. Check out some of the systems I have built using this method at www.urbanhydro.org