It is most definitely fixed this time! I checked the velocity by cutting 2 inch lines with x-vel-cmd in halscope running. The velocities were spot on with commanded vs. actual.
The acceleration however was way off. I adjusted the MAX_ACCEL in the ini file match commanded vs. actual and I am actually cutting better than before! I also ran arc voltage that helped me see that 1 out of 5 pierces, the THC delay was a bit too early causing erroneous sampling. I am assuming that the acceleration problems were due to gantry weight, friction, driver and stepper limitations, etc., something Rodw mentioned. And thank you Tommy for the idea of checking! I know verification should be the first step in troubleshooting, but I seem to run around with blinders on sometimes!