John,
Two suggestions:
1. I have experienced the same symptoms in the past, and it turned out
to be the bolts securing my Y axis nut (which has a square flanged base)
moving under the inertial load of the table.
2. My approach to machining the part might be to not cut the box section
to an L section.
Square off the end of the box section.
Mount a hard endstop on the side of the vice (or clamp something on the
table) to act as a left endstop and reference.
Put the box section in the vice.
Machine the top face (for example: the face with the two elongated
holes), but leave maybe 4 tabs to hold it in position. Don't do this
right at the end of the box.
Remove the box, rotate 90 degrees, and grip again, against the endstop
and with the other_face_to_be_machined uppermost.
Machine that other face (the one with the circular cut-out), perhaps
leaving a couple of tabs to hold it in place and make sure the box
doesn't try to collapse inwards.
Remove the box and manually cut the tabs.
Marcus
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