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Thanks very much for your advice!
I've changed by drawing code and can now see the problem, it is completely (well mostly) my own.
Basically, my problem can be characterized by pulling the rope over a thin block. The revolute joints aren't strong enough to keep the blocks together, so they stretch apart, and then some sneak down one side and some sneak down another. The way I was drawing the rope (by connecting the center points of each block) makes it look like the rope is going straight through the pillar, but in fact the different blocks are slipping down each side.
I'm now going to investigate different ways of doing ropes, probably involving much more overlap of the individual blocks.
Sorry for misleading people, I'll now experiment different ways of doing ropes!
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