The error I get from the first program is arc move in concave corner 
cannot be reached by the tool without gouging. I also see that you set 
the tool table but fail to load the the tool length offset with G43 so I 
assume your not using that. I'd have to say (without laying it out in a 
cad program) that your lead in move is one that creates a concave 
corner. I'd suggest an arc move into the large arc or one that is more 
aligned with the path of the arc.

File 2 is an easy fix, move the G41 above the G0 xy line so the lead in 
move is a x and or y move that is longer than the radius. A G41 then a z 
only move cannot work.

John

On 5/17/2012 2:02 AM, Speaker To-Dirt wrote:
> Hey Folks:
>
>     I thought I had tool offset
> figured out years ago. I have this simple project and it's driving me up the 
> wall. I can't figure out why my exit conditions and entrance are
> not working. I'm running EMC2 v2.3.5 on Ubuntu 8.04. Yes it's obsolete
> but the atom board on my mill won't run under Lucid (10.04). The mill is a 
> converted Bridgeport Series I (No longer BOSS 5/ Now EMC2) CNC stepper.
>
> This program is throwing errors saying my exit condition and transition from 
> G41 to G40 is going to cause a gauge.
>
>
> ------------------------------------------------------------
> F12.000
> G17
>
> G10 L1 P1 R0.127 ; The 1/4 endmill keepout larger for roughing
> G10 L1 P2 R0.125 ; The 'finer' tool.
>
> M6 T1
>
> G00 X0.000 Y0.000 Z1.000
>
> G00
>   X-1.000 Y0.000
>
> G41
>
> G00 Y0.746
>
> G00 X-0.072
>
> G01 Z0.000
>
> o1 repeat [20]
>
>    G91
>      G01 Z-0.015
>    G90
>
>    G01 X-0.072 Y0.746
>
>    G02 X0.473 Y-0.581 I0.072 J-0.746
>
>    G02 X0.400 Y-0.572 I-0.032 J0.039
>
>    G01 X0.271 Y-0.387
>
>    G02 X0.279 Y-0.320 I0.041 J0.029
>
>    G03 X-0.029 Y0.424 I-0.279 J0.320
>
>    G02 X-0.082 Y0.465 I-0.004 J0.050
>
>    G01 X-0.121 Y0.688  ;<---- code is stopping here on pass 20.
>
>    G02 X-0.072 Y0.746 I0.049 J0.008
>
> o1 end repeat
>
> G00 X-1.000 Y0.000
>
> G00 Z1.000
>
> ;G01 X0.000 Y0.000
>
> G40
>
> M2
>
> ----------------------------------------------------------------------------
>
> This progrprogram is saying my lead is is incorrect. ....
>
> ------------------------------------------------------------------------------
> F12.000
> G17
>
> G10 L1 P1 R0.127  ; The 1/4
>   endmill keepout larger for roughing
> G10 L1 P2 R0.125  ; The Mill
>
> M6 T1
>
> G00 X0.000 Y0.000 Z1.000
>
> G00 X-1.000 Y1.000  ;<--- Axis complains this is an invlid lead in.
>
> G41
>
> G01 Z0.000
>
> G01 X-0.088 Y0.499
>
> o2 repeat [10]
>
>    G91
>      G01 Z-0.0119
>    G90
>
>    G01 X-0.088 Y0.499
>
>    G02 X0.291 Y-0.415 I0.088 J-0.499
>
> o2 end repeat
>
> G01 X0.350 Y-0.300
>
> G00 Z1.000
>
> G40
>
> G00 X0.000 Y0.000
>
> M2
> ------------------------------------------------------------------------------
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