RE: Servo melting problem...
jetflyer
Hanger Nine makes a real nice amp meter. it connects between servo and receiver. it will tell you immediatly either voltage or amperage that servo is drawing. I used it the other day for setting up dual inline 8611's on buddies F-84. We eye balled linkage as close as ball and then used matchboxes to fine tune it. I plugged up the amp meter and sitting at neutral the two 8611's togther were pulling .45 - .51 amps. So much for the eyeball theory. With the amp meter install i could fine tune the servo's neutral and endpoints down to .13-.17 amps. VERY COOL TOOL not only for determining what a servo is getting voltage wise...but also how much amp it will draw.
I know this won't fix your problem but it will show you your problem.
I hope it helps you some.
Jetfreak