Hey, thanks for the compliments, Vanilla Ice! I still got a bit more to show off though.
In a previous picture you saw the controller from the right-hand side; this is the left-hand side showing the key switch and the U-shape bike lock & mount.
I cut a piece of aluminum angle to mount the controller to the bike rack. The plastic shell on the controller is on top and the wires all exit down, so rain shouldn't get inside, and if it does somehow it will simply drain down the wires coming out the bottom. The key switch is mounted with a 1" nylon cable clamp. I had to wrap the switch with a few layers of black vinyl electrical tape to build up it's diameter so the camp would hold it.
Since the battery bag is so small, I had to come up with some way to carry my U-lock somehow. I usually have a backpack when I ride, but not always. I screwed a couple of 0.5" vinyl-dipped clamps on the side of the bike rack to hold my lock. The lock swings a bit when I ride, and it gets scuffed by the wheel (picture 089), but it doesn't bother me when I ride.
The controller is a high-voltage but low-current 72V 20A controller. The original idea was to use one 36V battery for lightweight commuting & shopping, two batteries in series for a one-time high-speed run (to prove I could do it), and two in parallel for long distance rides. Unfortunately, I've had *very* bad luck with controllers with this bike...
I blew up an irfb4110 modified controller last May, when I went on my 72V maiden voyage. I then put a non-modified controller on the bike, set aside my hopes for membership into the 40 mph club, and rode the bike with a single 36V battery thru October, when it got too cold for me.
While taking these pictures, on a whim I got out the key for the bike and tried to turn it on, and heard a sickening pop... I'm so angry! Someone needs to make a robust BLDC controller for these bikes!
A piece of Masonite wood holds the battery bag to the bike rack. The bag is actually for toiletries when you go on a vacation or business trip. Two Andersons connect the battery to the controller.