I checked both my PC BIOS's.
My internet PC (that all axis's worked on). BIOS parallel port setting was [ECP].

My CNC PC was set to [SPP]. I changed it to [ECP]. Good results, well, better.
Now had axis Y and 4 motors turn for a split second and stop (when using manual jog [tab key window]).
Played around for a while, changed dip switch setting on one problem axis for speed, no effect.
Set to 35Khz, my Mach3 original setting was 25khz. nil effect.

I changed the manual jog speed settings from 100% down to 60%, SUCCESS!
Still not real sure why, I am guessing I had exceeded some speed capability somewhere.
loaded a G code (road runner), looked to be working fine (bench test motors only).

Comfortable to start working on my hotwire CNC rig now.
But I can see that the software configuration is where it's going to cost me the time. Mach3 seems bigger than Ben Her at the moment.
Still have to tune it all in once I build my hardware.
Still have to work out how to interface it with Profili2 (RC foam wings / G-code).

Thanks heaps for your input guys.
I will try and add some newbie tips as I plod along discovering issues that may seem a little basic to you guys.
Appreciate any and all advice/comments.

cheers
Rick