Thanks again Cosmin! Absolutely sure it's the wires, the lid was off and they were glowing! Probably just dodgy wires. As for the silicone suggestion, we're going to move over to Turnigy Silicone insulated wire instead. The Pololu 25D motors we are using have a current draw at stall of 5.2-5.4 I believe so I'm really not sure what could of happened short of terrible wire quality!

Thanks for the advice though, I'll give it a shot with some #22 AWG wire from Turnigy and hopefully be back in this thread with the results by Sunday. I had no idea about silicone insulation so thanks for that bit of advice!