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Is this a drivetrain issue (we are using the regular helical gears/gearbox/drill transmission for our prototype)?
We had the same problem after we built the nice little gearbox setup first game us. After we built our real robot frame and trainy we have run the robot through ever possible thing in sight including people on chairs. (Going at 15fps) Its very hard to get the motors to draw enough current to cause the autoreseting breakers to switch. We found that the shafts on the gearboxes were slighty bent and we believe this was the problem to the mass current draw through the gearbox assembly that first gave away. I must say that chances are you have to order some good quility 5/8 keyed shaft and make sure your spacers and bearings are in good condition. Look for every little thing that could cause the motor to work harder then it should. It doesn't take much resistence to make the motors work many times harder then they should.
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