Duralight rates their regulators with a 1 amp load. I have their 5.6 volt regulators on some Li-Po from RadicalRC, and when I measure the voltage from the regulator it is 6.5 volts under no-load. Even with their 1 amp load attachment it is 6 volts when having a fresh battery. Remember, a fresh charged 5 cell pack can be over 7 volts right off the charger.

Maybe your voltage is too high because there isn't enough load from the ignition module to bring the voltage down. There is a new regulator out there that looks like it will regulate to a set voltage with or without a load. I think this is a much better idea. I feel the Duralite regulators don't do that good of a job if the need such a large load to get the correct voltage.

I will try and find the link and post it, but I would change to a 4.8 volt 1650 mah NiMh cell for now as a minimum and enjoy flying.

The overheating problem ison CH ignition modules. I don't know what 3W uses, but if you contact CH, the will fix the ignition very quickly. Great people to work with.

Mark