[Bob649]

Hello all,
I found it - it was multiple faulty cables to the sidecar. The only one that works is a new flat cable from this year that I repaired according to the instructions on the KoP site. It looks like I probably had two problems at the beginning and after I fixed the other one, had the faulty cable issue. Once I got it running, it has been stable.

I will post some photos is anyone is interested in seeing some documentation of an end to end system including some scope shots of traffic.
I guess the "bad" cables must be good enough for the low order PWMs and other channels we were using to fool me.

So the moral of the story, even if you are sure your round cable is good, ONLY use a new flat cable without a twist until you get it working. Then switch other items one at a time so if it stops working you know what it was that went wrong.

Thanks to all who replied!

Bob