Update from last post....i done some research on the flat circle and basically it was either slack or tightness in the axis. On looking and testing machine i knew it couldn't be the slackness as the machine is built like a small tank at the moment. Basically the x axis could be pushed with your little finger but the y axis had to be pushed hard with your whole hand.
Stripped the y axis off the machine reset it etc etc but still a load of crap.
Found the x axis was smooth and by the time the y axis had enough torque to reverse, the axis was stationary for a small time whilst the x axis was still moving hence the straight line.
Put my hand in my deep pocket and decided to get rid of the drylin rails and replace them with some hiwin rails.

Completely stripped the axis down again and fortunately the holes lined up and replaced the rails. Remade the z axis plates which were bolted to 4 Hiwin carriages.

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Finished off making the aluminium plates for the motors and bolted these to the rails .......

Test cut revealed i still had a flat spot so i was well P**** off.....loads of money but no fix....

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Further testing and found the large aluminium T5 pulley was a second(ish) behind the smaller pulley on the motor. Stripped it down and found the grub screws loose....tightened the up, put machine together and tested....

WEEHHHHHEEEEEEEEE

Perfect circles and squares...Well worth the money.

Now i can start making the machine look more cosmetically pleasing as now i know it cuts perfect.

Well pleased. Updates to come.

Skiprat