Hi Dave:
Thanks for the idea. I had already checked that and found no problem. The machine is very tight. I did seem to find the solution though. In searching the forum I found that having the acceleration too low can cause a problem in the corners. I doubled the acceleration and also set CV off at 86 deg. The corners now come out 100%. It looks like I am now ready to really make some sawdust. Thanks again- and I will post a picture of my creation. It is really not my own design, but rather a unit created through the ideas from CNC Zone. Ahren for the guides, Dumpster CNC for some great parts, Gecko for the 540 drive, Keling for the motors, 8020 Surplus, etc, etc.
The computer is a whole other story. I started out trying EMC2 and after upgrading two old computers to find one that met the latency needs of EMC2. Then only to have the latency go sky high after UBUNTU updates. After the second time I stole my wife's XP machine, put in the video card I bought for the EMC2 failure, purchased MACH3, and never looked back. I did have to get my wife a new computer though. I should have just bought MACH3 from the start-- it is one heck of a nice piece of software. If anything the price is way too low for what it offers, and the support is second to none.
Thanks again for the help.
Jim