Alright, grabbed new pc, downloaded and installed fresh copy of Mach 3. Got my portable vise and digital calipers out, ran calibration on each axis using the Mach 3 utility for 5" moves. I did this until I got 4.999 on X and 5.000 on Y and then I did it 5 more times getting consistently 5.0 +- .001 Even if my calipers aren't the high dollar ones, it consistently gave me close results. So at this point you would think everything is good to go. Restarted Mach 3 and cut Grahamns file, results are: Outer dimension of pocket; expected 1.0 got 1.025, Inner Island dimension; expected .175 got 1.50
It's .025 off, how can it be off .0125 on each side when i did sufficient calibration to get 5.001? I did another calibration check, 5.001, It's like calibration and cutting are two separate entities, neither one has anything to do with the other. What's unique about this .025? it's always been off in this area, .020 - .025. On the controller, if it's supposed to be 1/8 step, but it was strapped for 1/2, or vice versa, would this be real obvious, or could this be a reason? Or maybe the controller is just bad in some way? Pc is ruled out, software is ruled out (CAD/CAM and Mach 3), gcode issues ruled out, system appears to be able to calibrate, but fails with .025 overcut consistently. Motor to lead screws coupling is tight, can't change the threads per inch, no backlash noted especially when it's .025 over all the way around. New Router, less than 4 hours on it, new bits, no runout detected. This doesn't leave much but the motors and the controller. And it would be real nice if the builder would return my emails!
Mark