battery packs
One thing that may be relevant is the type and quality of battery packs that we are using. After talking to Larry at SR I learned that the AA size cells may have a lot of capacity in terms of mah, but they may not provide the high current demand that we are asking for with multiple digital servos and ECU's on-line etc. After considering this I have switched to a 5-cell sub C battery pack. These packs provide a higher current than the smaller diameter cells. They also have heavier leads coming off them than the AA packs have.
I am not sure how much current the switch is able to handle as well, but these areas might need to be explored in terms of how they might be related to the potential for this clipping phenomenon to occur. We may need the expertise of an electrical engineer colleague to help out with this.
Mike Danchak