Update on this problem :-
1)?? Problem exists on all versions of Eagle installed (7.7.0 , 9.6.0 and 9.6.2)
2)?? Problem only appears if "Top stencil" is run with Bottom outlines"
3) ? Downloaded a fresh copy of pcb-gcode and used new copy of pcb-gcode.ulp.? Problem still present.

Attempted to run new copy but opening setup screen was incorrect and when run it complained about not finding javaw.exe.? Puzzled by this and dont know where to look for configuration - couldn't find the file anyway even though my working copy of pcb-gcode runs fine!!? Another mystery to solve.

I've attached a number of screenshots the illustrate the problem - hope they help clarify the problem.? All parameters of pcb-gcode were left unchanged for all test screenshots, and are identical to those used for CNC machine operation

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So as I understand it:

Hi John, thanks for your suggestions /comments, you will be pleased to know I have eventually solved the problem though not without some hiccups along the way.? I checked the toolpath in 3D and it appeared OK, all the cutting paths were at the specified depth.? To my shame I couldn't at the time find the download link on this website so eventually found it on git_hub!!

Part way through my investigation the "ulp" complained it couldn't find java.exe (I presume javaw.exe had got lost too??), so latest java.exe was downloaded and sanity restored.? A plus was that for the first time the inbuilt previews worked, so I guess java.exe had been missing for years? -? very disturbing!!

Had to reset all the pcb-gcode settings as they now appeared as defaults with BOTH etch files now showing errors!!??? OMG what have I broken now ??? Finally resorted to trial and error adjustment of both Eagle design rules and pcbgcode setting and machine settings and many hours later I have eventually found values for all parameters that produce? apparently good gcode files.?? Happy to share these once proven by milling a board.

Regards,

Peter.