OK here is the latest find, hooked up the laptop and ran a few pockets of different parts and everything worked great, i also noticed in the bobcad header a different post processor than i was running, so i found it and reconfigured it in v25, went back to the window box ran new tool path and it was 99% better but still had a very slight radius in the corners except the starting corner and it was square. So i am going to hook the computer with win7 on it tomorrow and see what happens, it could be that win7 may have something to do with it and the post processor may have to be tweaked a little. So glad to say it isn't the Controller and i did find that the controller from unique at least the early ones has a Gecko drive in it.
Thanks all
will update tomorrow's progress.