And now for the rest of the story...
Last night I tried the suggestions, Hibernate, Bios settings, Sherline mode. all with the same results, Motors ran smooth in the drive tuning but as soon as I saved the settings and went back to any main screen, the motors ran rough and periodically stalled. the motors would smooth out if I moved the mouse.
O.K. time to try something different I thought. Disconnected the lathe computer, Hooked it up to the Router. Put all the same step resolutions, Accels, Velocities in. Voilla! Smooth as silk! I was able to actually increase the rapid a bit from what I could run with Wincnc.
Lathe computer, 1.8ghz P4 IBM Netvista able to run @ 199khz. XP service pack2
Computer I WAS going to use for the router, Dual core 3ghz IBM Netvista, XP service pack2
I have to conclude that either Windows, or Mach do not utilise the dual core processor properly, at least in my case.
Hope that helps someone else,
Cutmore