Darvos,

>>I had the aileron setup at maximum mechanical advantage,

Well, it sounds like you did everything right. I don't have a clue what the problem is with your plane, but I still don't buy it's a general design flaw because mine and the 100's of others that are flying without problems would all be scraps too if that was the case.

>>as I really don't see the need for crazy aileron throws for most 3D maneuvers

You're right, most don't, but the ones that do do. If you want an all around 3D machine capable of all 3D maneuvers, you need the big ailerons too. Leaving big ailerons off of a plane advertised to be 3D capable would have been a design error.

>>The bottom line is if you are going to produce am ARF aircraft with these mods, it should be setup for it.

I believe it is. Your problem is not unique, but it is a rarity, which as I mentioned points to a problem in your specific plane, or in your setup(which sounds right on from your description).

>>I don't think 20 more oz's of torque would make a diff in what happened.

You're right, the extra 20 oz on your plane probably wouldn't have made any difference.