My apologies for getting back to you so late. It is very difficult to tell exactly what can be wrong with the car. As I've done for other customers before in the past in rebuilding their car, sometimes it is just a matter of some details and procedure of building.
Your bevel gear definitely is wearing prematurely, which in my mind, there is probably something that's not right. I would try taking the car completely apart, and slowly and carefully rebuild the car. Check every component, and make sure they are installed as per instruction. If you're still having difficulty, you always have the option of sending the car to me like we did for Kansas racer on this messageboard, that's up to you, I'm always here to help
As for parts, we will have the bevel gears back in stock as soon as the guys return to Japan (they are leaving tomorrow) and should be able to ship parts and car kits out to us by next week.
Lastly, I ran the PAL system over the weekend at the Reedy Race and right now, my PAL system spins almost as good as the stock system. I got the stock system to spin for about 16-18 seconds, and the PAL system right now, spins for about 13-14 seconds.
For O-rings, try using the orange or the silicon clear O-rings (1 in each end of the drive cup is enough) The Black O-ring is not flexible enough to seat properly in the drive cup.
Civic91, give it another try, it is a good proven car, and if you really need to, you are welcome to send it to me