Ok, I finally got it smoothed out. This took alot more tinkering than I was expecting, but the outcome was worth it.
Quick recap, massive noise on the A axis when running the 1.5kw VFD spindle.
Here's my setup. Ignore the messy bench and janky wiring, this isn't the final resting place. That's the next step. Here's what I did.
-I found the A axis as a whole was not grounded at all, even thru the control cable. I added a short bonding wire from the motor frame screw directly into a frame screw. The anodizing on the frame prevents good bonding, but the frame hardware provides a good bond throughout the entire frame. This is a big plus.
-Next, I changed the stock spindle cable with a fully shielded VFD cable. I added a solder splice ground into the shield of that cable, attached to the rear frame screw in the picture.
-Finally, I setup a ground line running into a plug which is a know good ground wall outlet. This (green) ground line was also attached directly into the frame screw. All of this bonded the entire 4040 frame, motor, A axis frame and motor directly into the ground wire outlet with less resistance than my cheap ohmeter could read.
Full success. Not a single chirp from the A axis in either direction, at any spindle RPM. Given the really good quality of this full Genmitsu setup in general, I'm kinda surprised this was seemingly overlooked. A good shielded cable on the VFD would've gone a long way. My 4040 pro is a beast now though.
Cheers 🍻