Thats exactly what I was talking about in your highlighted pic.
1) i thought that maybe the servo was the problem but I was wrong, the problem continues.
2) im not sure how much force is needed for the servo but all the gears are metal. What I cant seem to find metal is the hilighted part to the left in your pic.
I will check out the Kimbrough & definitely try the zip tie, thats a great idea.
I appreciate your insight on this & i'll keep at it till I figure it out. After reading uour input im really starting to think its that highlighted piece to the left, its a plastic piece that slips onto the metal gear of the servo. Why they would make that piece plastic is beyond me. I see other r/c brands have servo horns that are metal/titanium but im not sure if they would fit my servo, are all the servo gears(the gear that horn/saver slides onto) universal or do they come in different sizes?