We got the case back and ran it on our machine. We noticed the noise Selvey was talking about so we knew that something was going on. We couldn't figure out a viable solution that met Selvey's time frame so we just made a whole new case, ran it on the machine, noticed the noise was nothing like the case coming in and shipped it off to him so he could go play. I was hoping Selvey could give an update on his new case so we knew 100% that it was in and working as it should. I know he has been in contact with Todd and the outcome has been positive.
As far as the original case in question... we can replicate the noise. We can't replicate the heat issue yet. We tore the case apart and went over everything. One of the gear sets in his case was at the max spec that we say is acceptable. But we've had other cases with the same spec be perfectly fine. So we are going to play around with that gear set and see if we can fix the issue by tightening up the spec. We are going to stick it in a test rig and see if we can replicate the noise and heat issues in the real world instead of just spinning it in our test machine. But we have to wait for it to come back from the metal tester dude with the high end equipment who gets all scientifical to say what's actually going on with the part before we move forward.