Please help at wits end with strange offset tool paths

Perhaps this is the wrong place to post this but I am doing so incase someone thinks it may be within probe basic as the issue.

Problem: When I probe a corner of my 6-sided precision ground stock, and then run the tool path, the cuts are offset. At the probed Y side, the endmill is a few mm AWAY from the side not cutting and on the opposite side it is digging in a few mm causing a crash. It appears something similar is happening on the X side as well.

Machine: Taig CNC with linuxcnc 2.9.4 using probe-basic

Here is what I have done to debug:
1. Indicated my vise jaws, confirmed vise is in line with X and Y
2. Indicated my probe tip, made sure it is straight
3. redid probe basic probe tip calibration which results in a number in line with my other machines (I use the same aliexpress 3 axis probe)
4. confirmed the table is trammed, column is perpendicular to the table
5. Tested axis travel with a dial indicator mounted in-line with each axis. When I command movement of 12.7mm the indicator reads 0.5 inches so it appears the axis are travelling the correct amount (both X and Y)
6. Using fusion360, verified my endmill dimensions are correct (9.525mm), toolpath seems as usual, simulation looks correct

Additional information:
1. I added a screenshot of my 3/8 endmill on the side I probed, it is hard to tell but the endmill is about 2mm away from actually touching the side whereas it should be digging in 0.2mm into the side and cutting
2. added the start of my gcode file

Question: Do you all have any other suggestions on what I can try to do to debug the issue further? This is the only machine I have issues with. I have a linuxcnc lathe and tormach mill with pathpilot and both work correctly.

You have a probe diameter set in the tool table?

Does your probe calibration correctly measure the calibration ring/pin used?

Are you correctly setting up your cam post processor?

Have you verified using mdi commanded moves to rule out based cam settings?

Is your axis calibration correct?

Hey so I did another test - setting the origin manually with an edge finder makes it work as expected.


However, I can't for the life of me think of what the actual issue is in that case then? The probe calibration all looks correct, the diameter is set in the tool table.

When I compared the edge finder origin vs the probed origin, the probed origin is about 0.815mm off in each of the axis. The probe diameter is 1.95mm, calibration seems correct.

Do you think it is more likely a probe issue or a linuxcnc issue? Clearly the post processor/CAM is correct

I just can't think of anything mechanical with the probe being the actual issue

edit: My probe tip diameter is 2mm, when I do probe cal it says the probe cal offset is 0.97mm - and measures the circle as 5mm

EDIT2(MORE IMPORTANT): also if I use the probe to probe the edge, then move to the origin and slide the probe across either X or Y wall of the metal at the 0 value for that axis, it does retrigger the probe, doesn't that mean the probe is functioning correctly and its a linuxcnc side issue?