I think I may have figured it out. Started over again, re flashed the board, started new in the tx. Went thru the setup and it still did it. I put everything back together and kept playing with. It seemed to work until I set up the tx. I was messing around in the manual calibration screen and I noticed that the throttle wasn't reading full low. Not by much, just a couple clicks. I had to move low throttle end point to 104 and high to 103. Now that it was reading full low and full high in the GCS it works. Fires up every time.