Thanks Rich.
Hey Raul did you make any progress? Coincidentally I had a little threading job to do in aluminum yesterday that came out great. Even at 300 rpm in direct drive (too lazy to switch to 4:1 belt reduction) everything stayed in sync.
Couple things I changed, dunno if it was part of my problem. I checked "Spindle speed averaging" in the spindle tab and set my debounce to 2. The rpm DRO was WAY more stable after that. I ran the thread several times with good results.
I don't know if the spindle rpm is read by Mach (when threading) via the rpm DRO or directly off the index pulse input but my setup
appears to work better now. May have been the alignment of the stars & planets...or maybe the tinfoil hat I wore yesterday.

Oh almost forgot, I generated the code in Dolphin which shouldn't have made any difference but was easier (for me) than the Simple Threading Wizard. I also chose 14 roughing and 4 finish passes. In retrospect I should have doubled the roughing passes to reduce the load a bit as the last few roughing cuts were peeling off a healthy sized chip (for my little lathe.) It all came out OK so I'm a happy camper today. We'll see how things go down the road when I have to do "real" threads in steel.