what version of mach3 is the least buggy, and what are those bugs?
Not sure if anyone knows, or if it's documented anywhere. Since 3.043.066 is the one currently on the download page, I'd assume that the developers feel that is the least buggy. However, many users have found that version unusable.
Imo, Mach3 is not nearly as bad as you';re being led to believe.
Yes, comp (G41/G42) has bugs. But I use it for 90% of my parts, and have only had an issue with an incorrect toolpath once or twice. Don't use it in subs or with offsets other than G54, though.
You need to be careful when using subs, especially with offsets.
I'm not aware of the G2/G3 bug Terry refers too, and I would expect that 99% of mach3 users aren't either.
can i at least depend on one version to act in a stable manner if i am willing to avoid certain programming techniques?
Yes. One thing to consider is that if you're using an external motion controller, it's plugin may be based on a specific version of Mach3, and it will probably work best with that version.
I've had good luck running older 3.042.*** versions, and most versions after 3.043.028 are OK as well.
Iis mach4 really better? reading the mach4 forum section leaves me pulling my hair too.
You're not alone there. Many longtime Mach3 users are very disappointed with the current state of Mach4, and some of the decisions that the developers have made.