My apologies if this is a repost. I thought that I had posted it but when I went back it wasn't there so here i go again...
SOLVED IT!!
Replaced the MAX232 chip with a MAX202 chip, no other changes made to the circuit as the chip was in a socket and.... BOOM... it works every time now. I am not sure what the difference is and will have to go over the datasheets ( at a later date) for now I am just happy that it works....
I hope that this helps someone else out there..
THANKS to all who have responded.
Jimmy