Your right, now that i think about it, when i opened up a 249 mechbox, the pinion gear is actually touching perfectly [back of the pinion tooth lines up with the end of the bevel gear].
So like Flatlander said, there should be more tooth contact to cause less material failure.
So in conclusion, I guess the systema method either has a flaw or i just did it wrong
And make sure the pinion gear teeth are fully touching the bevel gear
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Well...helicals are different, yes. I'm sorry, I thought you were referring to "regular" gears.
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If these helicas break im never going back to them, I will just purchase Torque gears, BB's per second means nothing, gearbox stability > anything else.