Originally Posted by
atwooddon
Looking at the picture of the piece you cut, the overcuts are all in the corners where the bit is loaded on 2 sides. My guess is your machine is flexing as the bit digs into the corners. I also saw from your pictures the Z axis is extended a long ways down toward the table which makes any flexing more exaggerated.
Since you say there is no backlash, try this.... push or pull on the bit tip with the Z axis extended down toward the table (obviously with the router off). If you can easily move the bottom of the bit tip, even slightly, with minimal pressure, then it will certainly do that when cutting, particularly as it moves into a corner where the spin direction will make the bit dig into the corner. Now, retract your Z axis up to the point where the bit tip barely clears the bottom of the gantry. Now, try the same test, push and pull on the tip of the bit. The movement should be less. If so, try raising the piece you are cutting up to maximum height you can get it and still clear the gantry. Now recut the piece and see if the problem either diminishes or goes away.
If this is the problem, the only way you can fix this is to make the gantry more ridgid. Tighten bearings, etc.
Don