Well, I am the friend that's been having issues. Here is the thread on cnczone:
http://www.cnczone.com/forums/showpost.php?p=1624744 this thread documents the tests I have run now.
The code is generated in HSMXpress. As Ray noted, it has been hand checked. I have generated code that had the origin:
- in the center of the square.
- at points below and left of the square
- at points above and left of the square
- at points below and right of the square
- at points above and right of the square
In all cases my 90 degree squares (sides parallel to the x and y axes) come out perfect. My 45 degree 1" wide squares (sides are 45 degrees from the x and Y axes) are always coming out .956 in one direction and 1.042 in the other.
Note that I set up dial indicators and did testing for lost steps as well as for backlash and neither are occurring.
Not on that thread but another data point: I took the control computer from one of the CNC routers in my shop and put it on the mill. That Mach 3 installation functions perfectly on the CNC router. I copied over the mill XML profile and ran the test again. It came out with the same dimensions.