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Well, at least this particular problem can be ruled out from being caused by the dampers. I would like to remove them, but they are too hard to take out. So, I'm building a new printer instead...

I'd be curious to know if anybody with tricklaser arms has this type of problem. If the problem doesn't lie in the stock arms' orientation, it could be their joints... but why is it consistent across all machines? It's always the same side that has enlarged dimensions compared to the other.

I was just thinking that the dampers would allow the pulley to twist in a way that is slightly different than all the rest on the y axis, which is true. The moment load is different on that one axis, but I kinda doubt that's it.

I'm building a Rostock using the Trick Laser frame. I hope that will eliminate any possible tower twist as a possibility for the cause of something like this.

I'm using both astrosyn dampers and TL arms on White MAX and there's no dimensional error like what OP is describing. I had the dampers installed for a while before the new arms and there was no issue with the dampers alone. The ones I have use a pretty stiff rubber and I've never detected any motion to them.

g.

Moved the arms around, no difference other than I had to calibrate again.

Problem remains in the same position.

Also cannot see any noticeable bend on any of the towers.

The only thing I can think of at this point is either a firmware issue or one of the stepper motors is a bit wonky. The firmware issue is easy to fix - re-download the firmware from github, run eeprom_clear and then reload the firmware. The only way I know of to test for a weird motor is to swap the X & Y motors and see if the issue moves.

g.

Ill try the motor swap next... have already re-flashed and started from scratch once with no change.