OK! Got it sorted out. Mostly mistakes caused by my own mistakes.

The motors are 7.7 Volts, not 5 as I stated. The instructions for the
stepper driver
clearly say to use a power supply 1 Volt higher than the motor's
required voltage.
I was running all motors from a 5 Volt supply.
I whipped up a power supply from the junk boxen that puts out 8.9 Volts and
should be good to ~5-6 Amps. Y-Axis is much happier now.

The X-Axis (which hasn't had problems at low feed rates) will be happier, too
and will be able to use higher feed rates. Z-Axis (5 Volt motor) has always
been happy and very fast. No changes there.

The Y-Axis is hard to move by hand due to friction. All the linear bearings are
in good shape but the X-Axis sits on the Y-Axis and there's just a lot
of weight.

Would a double-stack NEMA 23 motor help me here? The stepper driver can
handle 3 Amps per motor. And I could add heavier (than TIP-120) transistors
to it off-board.

I'd forgotten many things about my DIY machine, having started on it in 2002
and working on it off and on since then. Fortunately, I saved all documentation
that I generated and was able to refer back to changes I'd made.

EMC is FANTASTIC! The stability, configurability and general "feel" is vastly
superior to all the DOS and Windows (non-) solutions I've tried.

Thanks to all who offered suggestions. It also prompted me to clean up
my nasty wiring.

Emory


-- 
Emory Smith
[EMAIL PROTECTED]
http://defoliants.googlepages.com

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