is it possible that a corner of the brake lining is not picking off of the pulley, and then starts heating the pulley up as the day goes on, and at some point the pulley has expanded enough that it's not clearing the lining. If the problem doesn't happen until the car has run for a while, it could be worth a look. Also are the fuses in the controller dual element or slow blow? They should go before the main line. Have you checked the connections in the main line for tightness, sometimes they loosen up and cause this situation. Just some thoughts, I have had all these happen to me. One last one, make sure you have oil in the gear box, and the gears aren't bottoming out.
