So youve provent Z isnt fully retracting even though the gcode is telling it to.
correct! We are getting somewhere now!! These tests you mentioned are great to rule things out.
want me to try to loosen base? I have no wiggle at all in there when clamp locked
can you post a picture of your z axis motor set up?
Yes, just for now make it really loose. Rerun the test you did and see if you can hear and see the Z-Axis struggle like before
OK, thatn looks good.
Sure thing, doing that now. What we will be able to see is if it moves right; as it’s stuck at this tension so now we can see if moves…
Yes, correct.
ok test 1 of that, went great! Went down an inch…then another 1/2 inch until I just went into back board like 1/8. Sent back up 1.5 inches, and the orange thing went almost to end of screw up top so stopped it! I will now go set to zero…top of board. Then run it down about 3/4, then send back up 3/4…and see if clips the top of board when moving sled off to where work board is. See if she returns to zero basically.
How are you setting the Z axis Zero?
ok success on test 2!! Well I used to used a piece of paper behind the sled and raise until the paper pulled out. I did that with router off. Now, I turn router on after I move to a burned up section with all these back cuts. I turn on router, lower slowly until I hear the bit just start to buzz the wood…you can sort of hear it. Then raise .001 inch increments…I move the sled 1 inch at a time up and down left and right, I see if leaves a trail in wood. If does, raise another .001. I wish I knew what this plate button is I saw in the settings, I would so set one up if easy. lol
How do you do it, so up for anything easier 
also for anyone happen to see the Zip Rip part of this post, as I wait for Jon to reply, I am looking more at the Zip Rip. I do not like how the hole for the pencil to use this attachment as designed comes down at slight angle so your pencil tip hits edge of tape measure edge. Maybe someone with a 3D printer can design something very similar to attach to the tape, then put in the 1/4 inch bit (backwards). My friend has one at the college he works at, will speak to him tonight to see if we can design something he can make for me to try Holey test using it. More to come
for right now I measure electrical continuity with my multimeter. I put a conductive plate under the sled and lower the bit until I get continuity between the plate and the bit.
The paper trick you use is probably just as effective.
oh wow that is awesome idea!! so do you take sled off and bench it? or do you have a spot off to side of the setup to move the sled over to? What a great idea!
I got the idea from the forum. It is also how the automated Z-Axis Zero option works. Except its done within Webcontrol instead of using a meter. This is what that button you mentioned is used for.
oh I have to find that and read up that ASAP! Awesome idea I am running test cut 6, finger crossed she works!!! keep you posted, has another few minutes to go… maslow is on the tabs part, so far so good…
Oh your cutting again. I thought you were going to o the test where plunged the router down an inch and then brought it up to see if could go all the way up.
OMG sorry it did not send from my phone! I sent a reply I thought!! Sorry, I did test, down 3/4, back up 3/4, smooth as can be on the up and down movement of router. I moved to the flat there is clean wood…no trails. Lowered it down .001, and hit wood!!! Test was a complete success