Hows the new setup? Which controller did you end up with?
I have been battling more with the buffer time... and somewhat frequently it still seems to just not do what I want it to do...
I am now using Linux CNC with the Mesa 7i76E ( the E stands for ethernet ). It wasn't an easy as "plug and play" because installing LinuxCNC was a bit of a hassle and I had to rely on my brothers help quite a bit with re-wiring ( of the relays mostly ) for the 7i76e and the VFD to talk to each other. Also the limit and home switches needed a bit of detail too ( basically the common leg had to be powered ).
Last time I used the mill the spindle was getting quite warm and now it feels very tight, so I'm going to have to take it apart to make sure its greased properly and not set too tight.
Jake