Ger21,
The sample cuts were done in two passes, 1/8" each, same as the other cuts. I feel the same way about it being on the second pass that is why I question the rapids... Could it be that the when doing a rapid it is loosing steps there due to the acceleration / deceleration being too much over a long travel? That was my thought when I was changing the acceleration in motor tuning.
GF357,
Yes thanks for that. That is how I had it set and that is when all the problems evolved. Now in the process of backtracking to resolve the issue of lost steps (?).
I will visit the shop later and copy the g-code for posting...
Thanks again!
ra
edit: Added g-code for "it works" pocket operation and the two alignment tests.
interesting note.... I did a simple cut for my daughter today. Went well. Seems to work as long as the cut can be done in one pass....