Just to be sure, its recommended to do atleast one or two full discharge/charge cycle to get full capasity.
Can you go into a little more detail as to what is happening?
Is it repeatable?
Is it the same servo every time, or does it change?
Have you tried positioning the bot so the servos are doing the least amount of work? Basically does the problem change depending on the load on the servos?
I hooked the two 10 year old Nicad packs up with heavier gauge wire to VS1 and VS2 (1 and 2 jumpered together). One of my much heavier NiMH won’t take a charge, that’s why I resorted to the oldies. All switches were removed as well as connectors except for the Deans Plugs at the pack.
I offloaded the camera load to an enclosed 4xAA case with 2500 mAh NiMH cells. (When Clyde was just a simple BRAT, this is what he ran off of just fine.) Camera ran and transmitted wirelessly for 25 minutes, good enough. Guns will run off of 9V cell.
I had a solid run of around ten minutes before the pack supplying power to the 5990's dumped at 2.3V. Clyde was walking and balancing on one leg the whole time! (ankle servo is a 645MG) No servo overheating at all, even pushing them at 7.2V. Nice tip, Jim!
Oh, and the lame servo issue… it helps if it’s enabled in your .cfg file!! So, its off to buy a pair of NiMH’s. Video coming soon!
Thats good news. 8) Now about your metal torso, how did you make that? did you design the parts and have them bent using big blue saw? did you custom design the feet?
Whooohooo! 
Now go out there and whoop up on Andy’s Hagetaka! lol Sorry Andy!
The feet and head I designed, cut, and milled personally from .050" 2024 T3 aluminum. I’m not handy with the press brake, so my buddy Milt lent a hand with the bending. I also made a mini-version of the SES electronics carrier to mount the AVRR board out of G10, but mostly, Clyde is all LM. I just found new ways to attach the standard brackets(L, C, Multi-purpose and 3" channel)
Very cool. been following your progress on the power issues you have had. sorry to hear bout that.
be good to see the vid.
your robot does look cool and i wish you the best of luck in the comp.
neat idea putting the batterys in the feet. the COG has really been looked afer in this build.
keep up the good work. 8)