Holy Smokes! I got it working. So I went out and found a Graphtec FC5100 (48") cutter in great shape for the crazy price of $500 (heck, cheap Chinese cutters are this much in 48"). The plotter "talks" HPGL but when I changed the "UNITS" to "INCHES" it didn't cut correctly, it was cutting very very small. So after some investigation and a review of the Post Processor Guide (viewtopic.php?f=4&t=6213) and then some work in excel, I discovered if I changed:

VAR FEED_RATE = [F|A||1.0|0.0166]

VAR X_POSITION = [X|A||1.0|400]

VAR Y_POSITION = [Y|A||1.0|400]

VAR X_HOME_POSITION = [XH|A||1.0|400]

VAR Y_HOME_POSITION = [YH|A||1.0|400]

VAR ARC_CENTRE_I_ABS_POSITION = [IA|A||1.0|400]

VAR ARC_CENTRE_J_ABS_POSITION = [JA|A||1.0|400]

VAR ARC_ANGLE = [Angle|A||1.3]

to

VAR FEED_RATE = [F|A||1.0]

VAR X_POSITION = [X|A||1.0|1015]

VAR Y_POSITION = [Y|A||1.0|1015]

VAR X_HOME_POSITION = [XH|A||1.0|1015]

VAR Y_HOME_POSITION = [YH|A||1.0|1015]

VAR ARC_CENTRE_I_ABS_POSITION = [IA|A||1.0|1015]

VAR ARC_CENTRE_J_ABS_POSITION = [JA|A||1.0|1015]

VAR ARC_ANGLE = [Angle|A||1.3]

It now appears to work. I'm not 100% sure that the 1015 multiplier is 100% correct but it appears to be. From what I can tell, the default mutliplier of 40 is against some "constant" of .025, so .025*40 = 1mm or 0.0393701 inches.

Can anyone explain why you have to even put a multiplier in if you change the "UNIT" to inches and why is the "constant" .25?

Otherwise it works great - I can even print directly from VCarve Pro using the "Output Toolpaths" function. I think Vectic is missing the boat by not adding in a few other simple post processors for all those other common cutters (USCutter,p-cut) - because anyone who has used expensive and poorly written applications like Flexi that are cutter specific, understands how nice it is to have one more value add function in Vectric products.

Thanks,

David