Hi Terry - the reason for my leadin/out cockup was I rebuilt the original curve simply by doing a 1 thou outside offset curve of it in Rhino but like a muppet I forgot to move those (manual) leadins/outs by a thou.
Had a bit more of a play and of course you're quite right that Mach has an issue with cutter comp and climb milling. However there were a few things I noticed about the dxf. Mainly that there ARE gaps between some segments - small - but there none the less. Also some curves didn't meet other curves or line segments at tangents (not that they should have to) - again very slight deviations but there. Anyway I cleaned up the dxf to address these two "issues" (just the scratch plate profile) and now Mach seems much happier - see enclosed .tap.
That said - as you say - there IS an issue with Mach but maybe this might go some way to explaining why the OP had some drawings that worked and this one that didn't.
Ian