Surf, Rough Pocket,.....Gouge???

[gavetta]

I'm noticing something strange if I have some certain settings in Surf, Rough, Pocket in X. If I have my total tolerance in the rough parameter page set to .001 it gouges. If I set it to .0006, it doesn't. I iges'd the file out and brought it into V9, set up same tool path with both settings and it didn't gouge on either one. It gouges around a boss feature (basically contours the boss but goes right thru 2 walls that it shouldn't). Here's photos:

The last photo is just the part.

Anyone else notice anything like this or have a thought as to what might cause this. I wondering if it's something in the control def/machine def??? This just doesn't give me a warm fuzzy feeling if you know what I mean.