Does anyone know how to handle the custom slicing profiles when switching firmware?

There's no touchscreen menu for this, so you can stop hunting through the wizard. The macro names themselves (START_PRINT, END_PRINT and the rest) do get picked up automatically, which is why your files still print at all. But that only covers the standard names. Any custom logic you baked into your zMod profiles lives in the macro definitions on the printer side, and Kiln OS ships with its own versions of those macros. Your old definitions don't carry over, same as the printer.cfg, mesh and PID didn't. The setup wizard builds fresh config files from scratch, it never imports your previous ones.

What I did was get into the config over the network instead of the touch screen. Fluidd runs on it, so open that in a browser on your PC, go to the config files, and find where the macros are defined. Then pull up your old zMod config and compare the two side by side. Whatever custom parameters your Orca profile passes into START_PRINT, things like layer change hooks or filament-specific temperture handling, you'll need to manually translate into the new macro files. Copy over the bits you actually customized, not the whole macro, since the stock Kiln versions handle the IFS and tool changing differently than zMod did. One thing to keep in mind: the print preview in OrcaSlicer only shows what the slicer itself generated. Printer-side macros run after the file lands on the machine, so the preview will never reflect changes you make to macros no matter what you do. That part is expected behavior, not a sign somethig's broken. If a print starts and the custom bits are silently ignored, it's usually because your Orca profile is passing a variable that the new macro doesn't know about. Klipper just skips unknown parameters without complaining. Add a quick log line or a status message inside your edited macro and you'll see right away wether it's firing and what values it's receiving.

I found that even after translating all the custom START_PRINT logic, the layer shift calibration sometimes gets off just from the filament changes. It wasn't the macro command itself that failed, but how fast the extruder could physically switch between the two materials. I learned the hard way that a simple brass nozzle tip jig made all the difference for maintaining consistent pressure when switching colors. Once you get the macros working, I'd suggest testing just the filament loading sequences with a dummy print, before committing to a full, complicated multi-material run. It's way faster to catch a macro bug on a simple test than wasting a whole night printing.

This is helpful because I tried moving my old start settings over last weekend and my first print heated the bed to the wrong temp and just sat there. Turns out half the stuff I pasted in was never even running, it just quietly did nothing. So when you say add a message inside the macro to check it's firing, where does that message actually show up? Is it on the printer screen itself or do I need to look at that browser page thing you mentioned? I've never looked at any logs before and don't want to poke around blind.

Total beginner question here but when you edit the macro files thru the browser thing, do the changes take effect right away or do you have to restart the printer? I ask because I messed with my bed mesh settings on my other machine last month, saved the file, and nothing changed untill I rebooted. Cost me two failed prints before I figured that out. Also is there a way to save a backup copy of the config before you start pasting stuff in? I'd rather not brick my setup the way I did last time.