Many mechanical problems were discovered during this 18 month ordeal.
The most significant repair was the quill and quill housing.
I realized the quill was getting jammed during Z axis servo drive tuning. Turns out the damage started years before I bought it. The Bijur oil metering valve lubricating the quill was plugged along with almost every other one on the machine.
I had Chinook Industrial do the repair.
First the chrome was removed and the damaged areas dressed to take new chrome.
It spent 32 hours in the chrome tank and then od ground back to size.
The only visible damage post repair
I then lapped the quill housing many times until I could just re insert the lubricated quill with light blows from a dead blow hammer.
Next was the Bijur automatic oiling system. All new metering valves, some lines and rebuild kit for the pump.
The X axis ballscrew was making some noise so it was removed at the same time. Disassembled, cleaned and re assembled.