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I think it would be helpfull to mention your previous os version and linuxcnc version, also include hal and ini pre-overhaul when the machine was operating properly.

Yes, you're right... it was XP. 

Here's how I found it.
 
 
 

Spindle:
 

Servos:
 

Encoder:
 
 

John was doing this
www.youtube.com/@Gnipsel/videos
See last 3 videos.

As a Canadian, I’ve always preferred buying from MesaUS. They typically use USPS/Canada Post for shipping, which is far more affordable than other carriers. However, today I did a quick search for their website and didn’t get any results. I'm unsure whether the site is temporarily down or if Mesa US has shut down operations altogether. John, the owner, has been an active and helpful member of this forum—hopefully he’ll chime in soon and clarify what's going on.
I don;t use step/dir cards in my projects but the 7i96 seems to be the most popular card for step/dir projects.