So I finally made it back down to the shop. Double checked all the settings per the instructions and everything is set right (3/4" stock, drill depth, etc). I even measured some screws and they are slightly less than 1 1/4".
I took one of the drilled pieces and placed a screw in it and held it up to the leg such that I could get the screw depth perception and I have to agree with a few of the other posts, it appears that the screw is driving to far. Not sure why I have never had this issue before, but who knows.
Not sure why I decided to put it so close to the edge, I plan to move it in a bit to the center and look to using 1" screws and play with the drill depth.
Thanks for all the feedback!