Wow, weird problem. It actually sounds like the voltage is too high if all channels run hot. This is a way long shot, but could the amp be wired for 100V operation and running at 115? I don't even know if Outlaw offers that voltage option, but I do think something is runnin up the B+ lines. I guess it could also be possible that the bias is too high in the output stage, but this seems unlikely as all channels seem to have the problem and all the amp modules would be built and tested seperately. 160 is way hotter than my 755 runs. It is warm to the touch, but 160 is basically untouchable. It really sounds like it is going back to outlaw for return. I will be very curious what the final outcome will be.