I finally got around to finishing my build nearly 2 years after I started. I am experiencing an accuracy and a possible noise problem with the Y axis. Below is a movie of the router trying to draw the arcspiral sample from EMC2 as well as a video. When the router is attempting change direction along the y axis it is making a horrible noise. There is no slop that I can tell in any of the axis and the marker is held firmly in place.
the final output printing the spiral: http://dl.dropbox.com/u/257902/DiyLilCNC/Y-Error-Example.jpg
a video while the machine is drawing the spiral, pay close attention to the noise the y axis is making. I'm not sure this is right. and there is a noticeable lag as it tries to change directions (67Mb .wmv file) http://dl.dropbox.com/u/257902/DiyLilCNC/y-error.wmv
thank you, any help will be greatly appreciated