An interesting discussion. Other points of high resistance, like a dirty roller pin, should reduce the current and reduce the arcing at the roller/center rail interface. The cause of arcing at the OD of the roller has to be limited to just a few causes. Excess current, low spring tension resulting in light contact pressure at the roller, contamination of the roller or center rail surface, rough or irregular roller or center rail, or roller is out of round. The roller material might also make a difference, I would have to think about that for while. Lionel did use different material for rollers used on one motor as opposed to two motor locomotives. I do not know when they dropped that or if there was any way to tell the different rollers with the same dimensions apart. I think if it was my problem I would look at the collector spring tension first. Not easy to do since what you are looking for is spring tension when the collector is on the center rail. Good luck. If you find anything please let us know.
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