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Quick update, got the new rails from CRP, installed them last night. Then over my lunch break ran home to test another cut and it seems the problem is fixed. Both parts seemed to match and line up....

Ok that makes sense, I think I will try that on all my Axis. I'm pretty confident it's the x axis rail causing my problems, but when I swapped racks they do have a bow to them as well.

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Ok bear with me spent all ####### weekend on this, I think I have figured it out. It started with me just out of a hunch measuring how far the z axis actually moved on top of the extrusion, which is...

Here's the gcode I've been using on the tests

372008

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I'll try that tonight too

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Yup I am assuming mechanical too I have tested with and without gcode with the MDI and can still verify the error. I'll be in the shop tonight to test a couple more things.

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Sure, other things to note yesterday installed new pinion gear, and swapped racks with X and nothing has changed. Another thing I noticed is that one or both of the racks I had off had a decent bow...

Yup first thing I checked, also remember I'm pretty certain this isn't a new problem I believe it has been off from the start, I just don't usually cut anything that needs to be all that accurate. ...

From my tests they were all about 1/16th this weekend I'll have more time to test and I will run different size tool paths to see if the error is always the same or changes

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I have manually moved the carriage with pinion engaged and disengaged to see if anything was catching or binding and did not find anything, honestly it doesn't make sense to me, I can pretty much bet...

Basically yes I can cut two pieces on each side of the machine that are the same width and on the left side it is consistently short to the right side
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I'm not following exactly how you want me to test with the indicator. Could you elaborate more please?

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Sorry should of been more clear my X is across the gantry my Y and A are slaved. No issues with Y or A just the X.

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No they are varying lengths, for testing tho I'm just cutting 3x21.5

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I have ran it twice just to make sure. Pinion marks and belt marks line up perfectly.

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Ok I will try that tonight when I get home

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Ok I am all out of ideas to test and looking for some more, I usually make more decorative stuff, but now have a project where all the parts need to fit together pretty accurately. I am sure I have...

I use Turner's tape from rockler or Peachtree. Peachtree Woodworking 1" x 36 Yards Double Stick Tape PW3599 https://www.amazon.com/dp/B0049RAEA6/ref=cm_sw_r_cp_apa_gFxzybAMVPFZV

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Also make sure your material is secured properly and you have no run out in your spindle

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Nice to see you guys keep being innovative. Keep up the good work CRP!

I wipe down my rails and racks with acetone then apply Super Lube 51004 Synthetic Oil with PTFE, High Viscosity, 4 oz Bottle: Fishing Equipment: Amazon.com: Industrial & Scientific to the rails and...

Nice, I'm going to have to try this out. Thank you for sharing!

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Hey everyone, it's been a while since I posted an update. The machine has been up and running since about May so for a few months. I have not had any problems with it, it is dialed in, pretty...

Thanks Gerry, probably going to do this tonight and measure with a tape over the length of travel.

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Ok so I have read countless threads about calibrating each axis, the only thing I have not seen is how you do your slaved axis. Can anyone answer how they calibrated the slave axis, or are they...

I have not cut mine out yet but I plan on putting them in the bottom birch layer and gluing them in so they won't come out. And I am going to use 1/4-20 ez lock zinc inserts.

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Alot of people use a spring or a gas strut

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Thanks nlancaster, I was thinking 8x8 at first then mapped it out and it didn't leave much options. I may go to 5x5 and use a closer cluster in the middle.

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To those that use threaded inserts, what grid spacing worked best for you?

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To be fair any machine you look at even commercial ones can run into these same problems. I don't know much about xzero cncs, but you can still have the same issues with loss steps, worn parts,...