Hi Phil,
thanks so much for your reply - that's really helpful!
Great to hear what you've been running boosted 4.5t with no problems - could you point me in the direction of any other sites with some good info?
I was running a 5.5t motor with a speed passion reventon pro running 90% boost and 7 ddrs setting. It was running reliably until I turned the ddrs up - the ddrs increase made it accelerate incredibly though!

it has two big fans blowing onto the motor and quite medium gearing and despite all the boost wasnt getting hot
I have been experimenting with a 3.5t motor and Orion r10 pro esc, only for a few batteries but rear belt seemed fine and car seemed reliable. Had problems with esc though..
I'll try running the belt loser as you say and see if that cures it as I had run it a bit tight before (some of the guys at my local track had recommended this).
where do you and the team guys race? I'd love to come and watch...
Ive only been doing this since Jan and am absolutely loving it!
thanks again!
Sam