Help! Please

[metalmaker]

I am trying to cut a sort of rectangle ring with fillet corners and arch top and bottom. This is thin aluminum with a bolt hole pattern in it as well. When I get the bolt holes to line up with a template that was run on another sb, the edges of the the ring will be larger than the template, sometimes on the sides, sometimes top or bottom. I have doubled checked everything mechanical I can think of. Unfortunatly I don't know the exact values for x and y as this is an older pr96. I have tried the calibration and it gives different numbers for x and y. Is this o.k.? I've been fighting this for days. Any suggestions would be great! Thanks Dan

[metalmaker]

Maybe I got it. I measured and calibrated with a tape measure and got closer than ever before. It still has a slight offset on the inner and outer portion of the ring away from the bolt holes. This is a seperate tool path and almost seems like it is not starting from the same home position, but I make sure the drill bit goes back in same hole I use to zero it. The entire second tool path is just about 1/32 to the positve Y.