[RamseyRuss]

Thanks again for digging into this so far - I hadn't thought that my post processor file could affect the code that much. I will take a look at the 204 line and see how mine is set.
(I have an older machine with very limited memory, so am sensitive to "excessive" lines of code.)

I watched the video (did you have sound? I didn't hear any) - I see what you were talking about with the blending; smoothing out the transitions. I'll have to think about whether or not I want that

So take a look in your post processor at this line:

204. Are the g codes (G02 and G03) modal in arc milling? n

I set mine to y and got a single G03 for each z line...