If you can, estimate the amps the motor is pulling.  If you don't have a watt meter you can use the charging current and time to measure how much gets put back in the battery.  Then multiply the volts, about 7.4 by the amps to get the estimated watts.  100-140 watts is a reasonable range for half A size planes on 35ft lines.

8500 rpm does seem a little slow.

I have an Arrowind and it's the last one. The first one from Brocraps was defective so returned it for a replacement. The first thing I noticed on both out of the box is the poor machining and alignment.

Maybe you are looking in the wrong place and the timer doesn't give 100% power comand.
You can check that out with a servo tester and see if it goes flat out to proper rpm when you commanded full poer
If it doesn't then I would put the fault in the motor. Volt x Kv slud give rpm.
Measure volt in battery then multiply with Kv rating give max on the servo tester and read actual rpn
Compare and draw conclusions

That 1650kv is a no load speed per volt. You might try a 5.5" diameter prop, or a lower pitch.

Install a very small prop and check RPM.  As stated the KV is for no load.  Then work your way up in prop size.  Too small of a prop will not hurt an electric motor.  Too big of a prop is death.  Right the opposite of a gasser.  Check you wattage as you go: checking it agents the motor speck max.

Also you might want to buy a servo tester.  It can be used in place of the timer.   They are cheep on the BAY

http://www.ebay.com/itm/Popular-RC-Acc-HJ-Digital-Servo-ESC-Consistency-RC-Helicopter-Tester-Tool-O1S3-/112570699203?epid=2255023215&hash=item1a35bc8dc3:g:cK4AAOSw5cRZLpe7

Or really cheep:
http://www.ebay.com/itm/Adjustment-Steering-Gear-Tester-CCPM-3-Mode-ESC-Servo-Motor-for-RC-Car-Airplanes-/322651775510?hash=item4b1f8b6216:g:1cEAAOSwU4JZkLfq

Hi Mark
Sounds like you have gone through a lot of checks that all affirm the motor is an 1100 kv - which is wrong for the motor (it should be a 1650) way to low for 2 cells.  Send it back for a replacement.

Normally the set-up as described works fine.  I use it on a Baby Clown that will do the OTS pattern.  I have also used that set-up on 3 cells with a 6x4 for a nice power-up.  in nay case it should be winding up a LOT more than it is.

Well, for now I just charged up a 1000mAh and three 800mAh 3S battery packs.  The flying weight was nine ounces with the 800Mah packs and 9¾ ounces for the 1000mAh pack.  I was afraid it’d be a dog, but the plane flew okay for roundy-roundy flight.  I didn’t try to see what it’d do for loops and such.  I just had my son launch for me and I did three or four laps to make sure it’d fly, then turned the plane over to him.  I forgot to put Velcro on one of the 800mAh packs, so we only did three flights on the plane.  I’ll charge the batteries back up in a few minutes and I’ll see how much we took out of them.  He only flew between 3½ and 4 minutes on each flight.  The motor was cool, the ESC was cool, and the batteries were not quite warm.  So, they are not being taxed in any way
Dennis, I was hoping you’d chime in.  I’m not one for sending things back.  Not that I’m shy about making noise.  More that I’m of the temperament of, “I WILL make this work!”  If I can’t make this work, then I’ll send it back.  I have at least one APC 6x4, I think.  I’ll work that into my tests.

Traian, I did the 3S for today, but I’ll try the 2S next week with some tweaks.

Target, I have some 6x3, 6x4, and 5xsomething props I can try.

John, I’ll try different things and probably make myself a chart for prop vs. speed vs. power.  I do have a servo tester, so I can probably work that into my testing somehow.

Keith, thanks for the info on the APC 7x5SF prop.  I guess at the RPM I’m getting, a Slow Flyer prop would be okay.  I picked up a couple at the hobby shop today, and I’ll give them a try.  Since the 6x5.5 isn’t taxing the system, the 7x5 shouldn’t load it down much more.  35’ Spectra is what we’re flying on.  I never thought of the white card to check no load speeds.  I’ll have to make up a disc and give that a try.  I picked up a couple of new 800mAh packs at the hobby shop also so I can do the testing with what are hopefully two known good battery packs.

Thanks for all the help, Guys.
Mark

I agree with Dennis, i had thought that maybe you were pulling too many amps, but if everything is cool after flight, that is not the case. An amp meter would surely tell the story.
Good luck,
Target

When I charged up the 3S batteries last night, I put 345mA back into one pack, and 385mA back into the other to fully charge.  About 100mA per minute for each flight.  Seems a little low.  The third battery, the 1000mAh, I just put on a storage charge and did not fully refill.  I cut a paper disc last night and will try a No Load speed test on the motor tonight.

Dennis, I will be careful.  I have a healthy respect for props possibly throwing blades.  I've had nitro props throw blades well below their rated RPM, so I am always cautious.

I'll make a chart, and possibly video my tests.