RE: .28 in a funfactor? oh dear....
Yes I went to the O.S. When I was looking for pinions one of the hobby shops made me an offer I couldn't say no to.
My immovable object was a 35 pound 1/5 scale. Those things are basically a wall with wheels. They did go through quite abit of abuse first and some really impressive high speed cartwheels. I was starting to think I got some weird experimental cvd or something from CEN.
On the strengthening issue I need to do some looking around but I have the ability to surface harden, temper, and even mig weld, there is also the possibility of having them chromed (might be to expensive) or powder coated. If that is a common place for them to break then the twisting is more than likely the cause and that is what has to be limited. I know of some machinists and cnc guy's, I'll have to talk to them about it. But I'm thinking a quick temper and some surface hardening will help them out alot.
rolland