@bcrazycramer i think it would be useful to approach the issue step by step. When doing a “home all” (G28) there’s not much that comes into place:
- Homing direction per axis
- Endstop switches
Depending on your firmware (i think you’re using Smoothieware which i don’t know too much of) you may also have additional settings like values for a move back when checking the home position or something like that.
As you’re getting good positions every now and then i wouldn’t worry about the firmware settings too much. I would check:
- Is G28 always the command that is getting used (when homing manually via the Host software it should be but also in your starting G-Code?)
- Are the endstops mounted well and can’t be moved by hand?
- Do the endstops all feel well in their switching position or may one be broken and switch differently every time you drive into it?
- May your bed be mounted unreliably? Does it come back out of the springs if you press it in?