K, so here is a little more information on our problem. I got this pm from another member and figured I'd post his questions here incase someone else would like to chime in...
Did you check ball screws?
Thrust bearings? Coupling?
I'm am unsure how to actually go about checking these out to see if they are bad.
Did you switch X and Y axis boards to see if problem is control related? That was the next thing we were going to do is swap out one board for another. When i tried to pull the board out it seemed very very tight in the slot and didnt want to break it so that is where we stopped.
Does It make a difference when cutting/not cutting? No it does this whenever it is running any type of program even if the cutter is not on the part yet.
Feeding? Didnt check will do so tomorrow
Rapid? Will also check tomorrow
Does it make a difference on travel direction? NO
Does it make a difference on climb milling? No
Conventional milling? NO
Does it skip when cutting only on the X axis with no Y movement? No it does not skip when just one of the axis's are moving. straight lines are perfect.
Do you have plenty of way lube on the ways? Yes, they are all very well lubed.