Since I am working with other Arduino projects on newer boards would it be more beneficial to work on getting a newer version of Marlin adapted, or will it not interface with the board properly?

You will still have the issue. It is the libraries that the printer controllers use. They are not supported by newer version of Arduino. If you need the newer version for other projects that's fine. Just download and install and older version for the printer. They all install in their own unique directories based on versions.

Yeah, I've had the printer up and running for about a year- and troubleshooting is just part of the game. You and heartless actually helped me set it up last summer.  Anyway, I would use the firmware that folger tech provides but I am getting an error under the sdbasefile.h folder when compiling it.

Arduino: 1.8.1 (Mac OS X), Board: "Arduino/Genuino Mega or Mega 2560, ATmega2560 (Mega 2560)"

In file included from sketch/SdFile.h:27:0,
                 from sketch/cardreader.h:6,
                 from sketch/Marlin_main.cpp:37:
SdBaseFile.h:38: error: using typedef-name 'fpos_t' after 'struct'
struct fpos_t {
        ^
In file included from sketch/Marlin.h:10:0,
                 from sketch/Marlin_main.cpp:30:
/Applications/Arduino.app/Contents/Java/hardware/tools/avr/avr/include/stdio.h:950:33: note: 'fpos_t' has a previous declaration here
__extension__ typedef long long fpos_t;
                                 ^
exit status 1
using typedef-name 'fpos_t' after 'struct'

This report would have more information with
"Show verbose output during compilation"
option enabled in File -> Preferences.

The issue is the version of Arduino you are using. The newer versions do not support the older style boards that most printers use. You need to use if possible version 1.6. Since you are on a MAC I am not sure if that is possible but try any version you can other than the one you are using. The older the better.

Here is a thread in another forum about the same issue.

http://forums.reprap.org/read.php?146,691608

Arduino: 1.8.1 (Mac OS X), Board: "Arduino/Genuino Mega or Mega 2560, ATmega2560 (Mega 2560)"

In file included from sketch/SdFile.h:27:0,
                 from sketch/cardreader.h:6,
                 from sketch/Marlin_main.cpp:37:
SdBaseFile.h:38: error: using typedef-name 'fpos_t' after 'struct'
struct fpos_t {
        ^
In file included from sketch/Marlin.h:10:0,
                 from sketch/Marlin_main.cpp:30:
/Applications/Arduino.app/Contents/Java/hardware/tools/avr/avr/include/stdio.h:950:33: note: 'fpos_t' has a previous declaration here
__extension__ typedef long long fpos_t;
                                 ^
exit status 1
using typedef-name 'fpos_t' after 'struct'

This report would have more information with
"Show verbose output during compilation"
option enabled in File -> Preferences.

I think we all may wish at times for firmware named after the great wizard of Camelot LOL.

If you insist on new  firmware then take it step at a time. Configure and confirm proper operation of endstops one at a time first and foremost. The motors will not work correctly unless the end stops work correctly.  Once the endstops are confirmed to be working by sending an M119 command through the host with all axis homed by hand and then sending an M119 command with all axis not home. Be sure the results for all endstops are the exact opposite in both checks and they should show as triggered in home positions. Make sure your connections on the controller for each endstop are correct for your printer design. Most of the time the endstops are plugged into the MIN connectors and not MAX.

Could you post a picture of your connections to your controller? Also post your M119 results both homed and not homed.

Then you can work on the motors one at a time. We will be happy to help you with that as well but lets solve the endstops first.

Right now I am trying to update to a new version of merlin

And I expect after that the machine will start working again, Like MAGIC !!!

Lmao, only in my wildest dreams.  Right now half my stepper directions aren't working, and the other half respond to different axis than they should.  I think its going to be a while before I get another print done...

Right now I am trying to update to a new version of merlin

And I expect after that the machine will start working again, Like MAGIC !!!

Tin Falcon wrote:
are you saving gcode to the sd card ??
Yes, through the tool included in repetier.

Had to ask I have heard of folks trying to save an stl to the sd and expecting to print.

I have direct printed from the sd card on my FT I3  sometimes sees the card and sometimes have to reboot printer. I use windows.

It is a bit crazy when we think about it.

Several flavors of computer OS windows MAC Linux.
A couple flavors of firmware Marlin sailfish repitier
several slicers
several  host programs
then many versions releases of each. 
so to work out the bugs for all possible combinations .......

When I run the printer direct from the computer i  get flashing on the LED on the I3 and some hesitation on the SD4.