thanks for the info guys.  

and maybe thats all it is... It will do it when I'm not on 3d rates... but I guess I do still have quite a bit of throw even on low rates.... and running like 30% expo.

just trying to get everything balanced  but I'm not seeing a major mechanical flaw... I'm going to check the servo's under load tonight.  how much force or weight do you put on the surface to accurately test the servo's