I agree that your current issues are probably the result of poor alignment because it looks like none of your plates are directly connected to each other. If you can make the gearbox out of a single piece of 4x4 I think that would help a lot. I would still suggest a larger worm gear though. You should probably go with bronze as Jared said, I have no personal experience with cast iron worm gears so can't say anything for them.
(I just want to say thrust bearings please)
Quote:
Originally Posted by Knufire
Worst case scenario, if you have the funds, you could purchase an AndyMark RAW Box.
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This is a possibility if you also decrease the cable pulley diameter significantly.