I like a lot of us have also had problems with melting spurs. I'd suggest that there are several reasons the spur can/will melt.
1.Incorrect mesh
2.Incorrect slipper adjustment
3.Worn clutch shoes or clutchbell (slipping)
4.Incorrect engine tuning
5.Broken parts (engine mount, clutchbell bearing, slipper bushing, spur gear, etc.)
All of them end up causing excessive heat and when that transfers to the spur gear, after a while the plastic compound melts.
What you need to figure out is WHY there is a heat problem, and WHAT is causing it.
Ok, sounds simple, but if you remember that it's heat related, then maybe you can help pinpoint where the heat is being generated first.
So, is your engine too lean? I've melted spur gears just cause the engine heated up too much, and transferred the heat to the spur. Granted I knew it was too lean, but was screwing around. Retuned the engine, and had no problem with the spur again.
If it's a mesh related problem, then you need to assess whether or not you are really setting it correctly, and if it's STAYING adjusted from tank to tank, or even as you are running through a tankful. So check after warm up, check again halfway through the tank, and then check just before you run out of fuel.. See that the mesh is still smooth, that the teeth aren't getting soft, that the adjustment nut is still a quarter turn from fully tight, etc...
Check that your engine plate isnt cracked, If it's cracked, the mesh will change under load... Check that your clutch bell isn't glazed smooth causing the clutch to slip and create excessive heat. Check that your shoes aren't glazed for the same reason. Use sandpaper to scuff them both up.
Now if all else fails.. (and I went this route just to ensure no further problems) Get a vented clutchbell, get a vented flywheel, and get aluminum shoes. I've got all three, and with a new spurgear, a new spurgear bushing, and the adjustment checked each time before I run.. I haven't melted another spur since.
Take a step by step approach to finding what's causing the heat build up, fix any problems, and possibly upgrade to some cooler running parts, and you should be good to go. I'd also suggest NOT getting a metal spur gear, as there needs to be a weak link so that you don't damage more expensive parts. In that sense, a cheap spur gear isnt as bad as a new transmission for instance!
Good luck and report back with your findings/results.
Vinny