[Jared]

Can you provide some details on your worm gear? If you could fix the worm transmission, I think it would be easier than designing a new gearbox.

We're using a worm gear in our transmission, and we've experienced no problems after tons of abuse.

I would recommend using a hardened steel worm on a bronze worm wheel if that's not what you're already using.

Also, you should be using lots of grease on the worm gear, and your alignment needs to be pretty accurate. If there is slop, or if things are misaligned, you can really wear out the worm gear quickly.

If you can, could you post a picture of the worm transmission?