I will go down and look at mine

All step low active and dir low active have a red x in them on mine

Same here.

are your cables shielded to the steppers?

Yes. Grounded on one end only. (main Gecko mounting plate)

If you have a dial indicator, you could write code to make the machine run in the X for the length of the machine and back lets say 10 times. I would do both at feedrate and then 2nd test with rapid moves. Lets first try to see if it is your rapids. Do this with the universal motor off (the router). Then do the same thing with the router on. 4 tests that will start giving a better idea of what is happening. Now if I remember correctly you have geared motors so I would expect to see 0.008" error on the return. So we are looking for something more than that.

You should run to the star ground in theory and all grounds run to it. That would be the correct way. That being said, I have seen that law broken and not had problems.

Did you leave the shielding on the cables up to right before the point of termination inside the electrical enclosure. I have see drives act weird if the wires are next to other power wires that are excessively noisy.

I left as much shielding as possible. (just enough to get the separate wires to their terminations)


Going to set up the "back and forth" test tomorrow.
Thanks for your help.

Lee

SOLVED

Needed to tune the drives to the motors.

They always sounded "okay", but I tuned them better then ran a X, Y, & XY rapid test at 300ipm rapid, 25ips/s acceleration.
(end to end ten times with dial indicator set at home position).
Came back to within .008"


I then ran my crisscross hole drilling test. Again came back to within .008" and holes are now drilled concentric (no offset)

Thanks for the help everybody!

Lee

Excellent news. Thanks for sharing the solution.