hi hawkeye
I sent you an xml file named hawkeyemill.xml to use to run your mill and its pulse per inch should be really close.
before calibrating with the autoset function in setup screen you need to set backlash compensation.
there are a few different methods but here is how i do it....
first you need to adjust the gibs so they are snug but not too tight
back off the gib untill it is loose and in step mode set to .001 per step, move the axis 1 step at a time untill you see a movement on a dial indicator against that axis. when it moves on the indicator zero the indicator. now move the axis the other way one pulse at a time untill you see movement and count the numbers of steps you made untill it moved and write it down -1 the last step made it move and we are looking for the steps without movement, or the backlash.
now slowly adjust the gib tighter until you see the steps required to see movement go up by one , this shows that the gib is just starting to bind the axis. back off just enough untill it returns to the original amount and lock the gib.
repeat this for every axis. on the z-axis make your measurments moving in the up direction it wont work moving down because of the free weight of the head takes out backlash.
now take you measurements you wrote down and enter them into each axis box in backlash compensation and remember to enable the compensation and leave the compensation feed rate at 20 percent.
dont forget to save your settings ( config pull down bottom of list " save settings )
now you can use the auto set in mach3 setup and backlash will be included in the settings.
steve