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I've decided to stop dealing with a company that is this unconcerned about my business. I understand my order is likely a drop in the bucket to them, but I wish to make progress not await someday...

drumsticksplint,

Any updates on the status of your order?

I ordered a 7I76E on 04/20/2015 from Mesa, paid for the card and 3 day shipping via my debit card; their website showed 4 in stock. ...

FYI: Lose the apostrophe.

"EMPLOYEES ONLY" is correct.

EMPLOYEE'S is possessive not plural.

Did you feel around to see what was getting hot?

It seems more likely that the power supply is in trouble than the parallel port, because you have adjusted the power supply and things got worse. Perhaps now your power supply is bumping into its...

I believe you have found the demon, since Gecko specifies the G540 for 18VDC to 50VDC supply voltage. If it sagged much below 18 even briefly, that would explain the fault.

Ummmm, what voltage are you running the power supply at? (Measured with no load using a digital meter?)

I'm guessing that your power supply is pushed almost exactly to its limit when all 3 axes are moving simultaneously.

When the machine is cold, grease and oil are thicker, etc. and the steppers...

33 1/3

I used a welded metal frame wooden table that was already conveniently located.

With enough time, a little bitty river carved out the Grand Canyon.

This guy cut a 12" circle from 0.021" steel in only a bit over 40 minutes.
YouTube - Routing Steel on K2 CNC Machine #1

A layer of cardboard would save the finish.

The "G Code" programming that Mach3 runs includes a FeedRate instruction,
here is a tutorial on G Code:

CNC G code Tutorial | Lumenlab

Your step and direction pulse widths look mighty small at ZERO.

1) Shims are your friend. Critical if you are as human as I am when making things.

2) Necessary resolution depends on the size of the carving you wish to make. 0.001" is likely to be excellent...

Don,

I like the way you used BNC cables and connectors, convenient and tidy.

John

A look at the file with a hex editor might be useful, could be a simple matter to shred the pieces back out, if it is not compressed.

Google is off by a smidge, the plant is HGR.

:: HGR Industrial Surplus - We Buy & Sell Everything! ::

I went to HGR planning to buy a ball screw they had listed, looked to be about 0.750" diameter and perhaps 24" long in the picture. When I arrived, it turned out to be about 2.750" diameter and...