thanks for the posts, found the devil.

Ger as always great advice. I found for large parts a tape and the camera feature on mach with crosshair works great for calibration. But yes, i concur with if you calibrate small and cut big you may have a large error on the big parts ( i would normally be a 1/32 to 1/16 off)

Well the last owner redid my rewire for whatever reason and used the home depot red bullet connectors on the encoder connections. Yup, not a loose but crappy connection. Must have not gotten all the copper in the crimp. I found it as i accidentally touched the wire and the machine cut that part wrong. After stopping the machine I wobbled it and the y started to move. Put my connectors back on and bingo bango no un-programmed movement.