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your piston/gear teeth engagement is off at speed.
You're shooting a pretty mild spring (guessing it's a m100) to get 270 w/0.28's. A stiffer spring will return the piston forward faster...in order to be picked up by the sector gear properly.
With a metal rack of teeth...either the rack will break (and probably break something else as well) or the gear teeth will break as it's setup right now.
Sounds silly...but you can "test" the setup with a 7.2v battery and/or a weaker motor first to see that it's running right...then ramp up to a bigger battery/motor.
Tys
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