[MrForbes]

A picture is worth a thousand words...can you post a picture of your setup? You may be doing something wrong that we can't tell from just your words.

Today we got about 35 feet travel from a single 8" kit wheel (from a few years ago) direct driven by a CIM, and less than 90 degrees of arc. We made the arc guide from a piece of 3/4" plywood, cut to the correct radius with a jig saw. We have about 1/8" compression on the frisbee as it travels thru the shooter. We also added a piece of wood on top to keep the frisbee from jumping up and losing grip.

One other problem we encountered is the wheel slipping on the motor shaft, we don't have the correct keyed hub yet.