I followed the advice you all gave me & checked / tightened / aligned what I could.
Retesting the x axis gave me the following figures that I'm pretty pleased with.
DRO Dial Gauge (all values in mm)
0 0 1.003 1 2.03 2 3.01 3 4.01 4 5.04 5 6.03 6 8.06 8 10.05 10I cut some test holes, a rectangular cutout and some circular cutouts. Both were within 0.05mm (~2 thou?).
I changed the cutting bit to a 2 flute 1/8" dremel router bit and got a much much cleaner cut with little to no melting of the plastic and little burr left on the edge.
Some pics here of rectangular cutout & circular cutouts:
Thanks for you help, you can be assured there will be more questions to come!