Well, I decided to upgrade again to 2.x and again I ran into major problems.  I wanted to cut a simple contour with cutter comp and it looks like it just can't do it without running off location by a lot.  Also if I shut down Mach and restart the location it runs off is in a different location on the tool path.

Below is a screen shot of what happens.  It is cutting the contour fine then at some spot it starts going in the opposite direction to what the code is telling the controller.  I paused the feed to take a screen shot but the tool was moving in the positive XY direction before the pause.  There is no move to the positive XY, at least the where the readout now showing.

Any insight would be helpful but i guess I will revert back to 1.9

I reverted back to 1.9.086 and it runs fine.

Could you please send me the file and I will test it on the newest comp code.
Thanks
Brian

Sorry I was out for a while.  Here are the dxf and gcode files.

Dan.

Okay I know this is not what you would like to hear BUT....

The problem is that your file is not able to be comped. The problem is that the line segments are to short... 
Here is a section out of your file:

X-0.1378 Y-0.9791
X-0.1366 Y-1.0146
X-0.1351 Y-1.0518
X-0.1335 Y-1.0902
X-0.1317 Y-1.1297
X-0.1297 Y-1.1698
X-0.1275 Y-1.2102

As you can see there is not much distance from move to move... The calcs for comp need to have line and arc segments that are longer then the length of the Rad of the tool. If this is not true mach3 has to skip lines and arcs! This can't be done because we can only see three moves at a time.

So you need to do this in CAM program (Fanuc would not do it as well)

Understand what you are saying and can adjust for it in the future I think... but why does it execute fine in 1.9 and not 2.0?

in 1.9 we tried to get files like that to work and found that if we did that it will not work on other files! Comp is a nasty problem and sorry that you had to see the problem