< snip everything and start over>

I was going to just pick on Ray but I think I will dump on the whole  
list.

In summary: this started out as inconsistencies in the homing of X  
(something like .03)

the lstg diagnostic/exerciser from stg gives interesting results.

X axis 2500 cpr encoder on ball screw and  plugged into ( )  on the stg
X        10K c/r
Y          10K c/r
Z           10k c/r

Y axis  2500 cpr encoder  on ball screw and plugged  in to ( ) on stg.
X           10K c/r
Y            random number of counts
Z            10K c/r

Z axis modular encoder 1000 c/r  on Z servo motor
X       4000 c/r
Y       4000 c/r
Z      4000 c/r

Out of all these combinations the only one that is flaky is Y on Y.

I'm a bit short on ideas but maybe I'm missing the forest for the trees.

Dave

BTW - it appears that the hal stg driver doesn't have an index  
output .... or am I again missing something. 

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