pic: Wheel problem.

[Nathan Streeter]

Yeah, a pic of how you mount your wheels to the sprocket would be helpful for advice; however, I'm guessing its how you screwed the sprocket onto the wheel... What I would suggest doing (what has worked for our team this year, and with the past KOP AM wheels) is using a 2" long 8-32 going on the sprocket through the entire wheel, with a nylock on the other end. Tapping may seem like a weight savings, but its a little more work, harder to repair/replace, puts the weight in a smaller area, and may loosen if you don't use LocTite, which can weaken the plastic!
So, I don't know what your team was doing, but I think if you reconsider the wheel mount and buy replacement wheels you should be fine!