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Hi Guys, in the end I deleted my Mach4 installation and the SmootStepper plugin and started from a clean install. This seemed to cure the issue. 

 

Please accept my apologies for wasting people's time on here and thanks for the replied in the thread. 

 

Lesson learned about DIY CNC: You do spend as much time getting/keeping it working correctly than actually making parts. When I grow up i might need to treat myself to a dedicated CNC machine. 

 

Thx, 

Patrick