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I went with a Gecko G540/ESS (Ethernet Smooth Stepper) setup on my Taig mill. The ESS lets me use a Win7 64-bit computer for control. The G540 has inputs for limit and/or homing switches. I'm running...

I get what you are saying. On my machine, I tend to get a nice finish on the bottom of pockets with an OK finish on the walls when roughing. I pocket to the finish depth with a roughing clearance of...

On similar pockets, I use a Pocket MOP for the roughing and follow with Profile MOPs for the finish passes. That eliminates cutting air.

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