If you command a move of say 1 inch does it move that distance?
Reason I am asking is I have just looked at your xml and I see you have the default 2000 steps per unit and I am wondering if that is correct for your machine.
Hood

yeah at 2000 steps I get a 50% reduction.  4000 steps is what gives me an accurate distance, however only the first line or two come out to spec.  The more passes the bit makes, the more the cut shrinks and drifts.

Have you tried Sherline mode?

Hood

Thanks Hood!

So far so good. I cut a 3 x 3 square and it looks good.  I've loaded in a heart to cut out for my wife for dealing with me the last couple of weeks.  I will let you know how it goes!

Also, back to the horrible screaching sound of the motors, even at idle, this can't be normal right?  I really appreciate the help!

Can you post a video of the noise?
Hood

I don't have access to a video recorder at the moment.  The best I can describe the noise is as a constant high pitch screeching.  Obviously once the router is on I can't hear them anymore, but they are still loud enough I am concerned.  How audible are yours?

Nobody in the family with a digital camera or a fairly modern mobile (cell) phone as normally they can take short videos.
The Bridgeport I have steppers on is reasonably quiet, the motors sing away at varying speeds and that is normal but you say yours are screeching so that doesn't sound right. It could be due to the old drives you have but without actually hearing it its hard to say.

Hood