I restored one of the earliest config files (April 4th) and restarted mach3.. same screen position.  Seems no matter what I do, change and save.. it ALWAYS starts half screen as in my attached picture.  I am getting to the point that something is really faulty and I might have to uninstall and reinstall the whole program.   

   I can easily drag open the window.. but it is very annoying.

Are you only dragging to enlarge ?
Did you try to use the RESTORE button ? then close and restart.
Russ

Yes, I have to grab the bottom of the window to open it since it now opens only half screen.  I'll try that restore and let you know if that resolves it.  Thanks.