Just to post the cure. A big thank you to Hood! Mach now boots fine and a different problem I was having went away as well!
My Z axis had been loosing position, fairly consistantly. I would put a dial indicator on it while running my parts so i could tell how much to change the wear offset and keep making parts. I had re-calibrated the steps, different drive, different motor (those were steppers) Even converted to a servo.
I reloaded Mach3, Ran ~ 100 parts and my Z axis was spot on! My X axis which is still stepper after ~ 50 parts was off a tiny bit, re-homed and all was well.
Thank you,
Eric