Please further describe the cogging you experience when starting up or when pedaling. For example, my Lyen controller causes my Crystalyte HT3520 to cog when I pedal so I assumed that was normal. Please also discuss the following factoids which seem somewhat inconsistent.
1. Marcus Hayes in 2011 responded to a question of mine that Picycle used a single sensorless motor that can easily take either 36V or 48V. I don't know what current it can handle beyond the 2C limit with 3 second 2.5C cutoff delay that the Allcell BMS provides. As Pi offered batteries of up to 48V and 15Ah I presume that 30A at 48V is not a problem. I question whether Pi has changed the motor since the version used on your bike. It appears that the diameter of your motor is less than the 210mm diameter of the front disc while the motors' diameters shown on both vaporware models on the Pi website seem to be greater than the front rotors concealed behind the hubs.
2. I have a Lyen 130V 18FET 4115 Infineon type Controller with a default current limit of 45A and Regen. What I didn't realize was that the controller required Halls which may possibly be the case with all Infineon based controllers. Is it possible that you are using a sensored Lyen controller with an unsensored Pi OEM hub?
3. What is the width of the flat portion of the hub axle? I suspect that Pi specced a heavy axle with flats in the neighborhood of 12mm and a front axle internal width of 135mm. Please confirm what will fit. Marcus once talked about (but didn't follow through on) marketing "Developers Kits" that would include dropout adapters that would accomodate more typical axle flat sizes. The following is from a 4/22/11 email from Marcus:
"The rear has interchangeable tabs to accommodate axle diameters ranging from 9mm to 12mm. And there’s sufficient surface area to go larger still (14mm) although this would be a permanent alteration. As you’ve surmised the front works differently. There are clamps located on a pivot point that secure the front axle. The clamping method nonetheless can accommodate axles in diameters ranging from 10mm to 12mm without needing permanent alteration. The front and rear axle spacing are identical at 135mm ID.
"I have attached some images for added clarity."
Did your demo bike come with any of the pictured adapters?