HI skarlot
Thks for your quick response.

I try out a few stuff

I complete delete the WTF files from both my WOW directory and remove all the addon.

I set both instance (toon1 and toon2) to 1280x960, UI scale off, windows mode, turn all the action bar on, and toggle on "always show actionbars"

After I launch wow. I will have 2 action bar on the bottom left(running Hoz), 1 action bar on bottom right (running hoz). and 2 more action bar right (running up and down on the right).

Octopus setting
Set Zone Main(0,0,1280x960)
Zone Two (0,0,1280x960)
Mouse setting - WOW mode on.

Launch both instance from Octopus. toon1 use Zone Main on display 1, toon2 use zone two on display 2.

If I setup like this all my mouse click will work fine. Each time I clink on the aciton bar in toon1, The same on will light up on toon2

This will work for a 2 box, but I am going to a 5 box, the setting will have to be change

I change Zone Two (0,0,800x600), relaunch both instance

This is when I run into trouble. ?(

When I look a the screen, I can see the action bar has move/scale ? differently on toon1 and toon2. 8|

ON toon1, it has the end cap (2 silver eagle?) on left and right bottom, toon2 do not have this. There is also an 1.5" gap from the bottom of the minimap to the top the of right action bar.

I am going to number the bottom left action bar from the middle of the screen out to the left side. 1 to 12. I am clicking in the middle of each button. 1-4 works. 5 nothing, button 6 will work button 5 on toon2, 7 will work 8 etc,

ON the right bar that runs up and down.
1 do nothing
2 works 3
3 works 4 etc until 9 it do nothing
10, 11, 12 works the same on both toon.

I am clinking the action bar on my toon1, clinking in the middle of each button.
I check the video setting on both instance, they are still set at 1280x960. The mouse clink is broadcast to the exact or very close position on both instance, but wow is scaleing the action bar differently on each toon . Even when the video setting is setup the same on both intance.

I am at my wits end. I will really like to use the mouse to clink and control my toons if possiple. Or, I will be spending a lot of time relearning, rewriting and rebind my keys.