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I don't know if I was any help actually, but you are welcome! Would love some pics of you babys :)

Seems like a great start! Personally I don't see any issues up front. Do you have a scope to watch the outputs?

0-500 A/D:
In my head, I see it like this. 1 timer for the 165uS time base.
2 software counters, 1 for X and 1 for Y.
These counters will count from 0 to modified A/D value.
If the counter >= A/D...

Bo, I'll pm about the site. Feels like spamming to discuss it here.

Deleted wrong information

Nobody ever hears mine either. It doesn't really matter if I understand what you intend to do. It only matters if I understand your question(s). So assuming I have the joystick operation correct, I...

Ok, I know I can be a bit dense at times, but I think I finally have it. All you really want to do is jog x,y to a point, fire the trigger(this will invoke cycle start or run), a program will run in...

1 more thing to think about. Homing. when the pic is reset or on startup, you need to home the drives of course. I would do this by jumping to my "home routine" first and wait for a button press from...

Sometimes I must laugh at myself. I know I read the third pot was to adjust the speed, but I still keep thinking about it as the more you move the joystick, the faster you go.

OK, re-read the...

are you using steppers with encoders?
the step/dir implies using steppers, the 360 cpr x 4 encoder suggests encoders. I ask for 2 reasond, 1 just because its pretty cool if you are closing the loop,...

Some prelimary questions: How fast do you want max jog to be? how many steps per rev? This info will drive how you toggle the output pins for the steps. My first thought is intrupt based toggle. But...