Maybe a few more notes for folks.
The use of Method's LCV boards and breaker board used backwards (to cut off battery power to the controller) has worked well. Saved our pack a few times already. I thought it was charged one day and I tried it a couple of times thinking something else was wrong. After hitting the reset button a couple of times and getting power for 10 seconds then none, I realized that the LVC boards and breaker were doing their job cutting off bike power as soon as any cell got too low ( < 3.0 volts).
2nd Bike I just built:
http://zuki.net/picslive/Gray-Element-Ebike-Build
I've since built another Element 2008 bike (above) the same way and just got a second pack built. Its a lot of work wiring and bench testing the breaker function in the pack. The easiest way is to unplug one of the battery leads to an LVC board, then inject a 2.5V signal into each channel to make sure each cell pins trips the breaker. I should do a write-up on this. Methods told me how to make an DC 2.5 volt power supply by taking a 5.0 volt power supply and using a voltage divider on it with a couple of 1K resistors. Then you can put 2.5 volt and 5.0 volt leads off the power supply. Testing the way I described is as close to a real-world riding-down-the-road-test as you can get. It does not verify the battery leads but it at least verifies all your finished wiring and the proper functioning of the boards as intended.
I am not happy with the rims I got on the BMS kit that I mentioned that came with the Cute 100 motor kit. It worked okay with a 26x2.1 wire rim tire, but I could not seat a 2.2 Maxxis foldable tire I was trying to put on. So I bought a Mavic XM 319 disc rim (< 500g) and all is well. I used the spoke calculator at ebikes.ca, got them to cut me some spokes, then got my local bike shop to lace the cute 100 hub into the rim with a strong 3 cross pattern. The Chinese rim only had 1 cross and the spokes were not even touching - so the crosses were not adding any strength.
We've had no problems with the two Cute 100 hubs. I put about 70 grams of Fluid Film into one of them to protect against the rain. It does not leak out when the bike is lying sideways, like my older Bafangs did. So they appear better sealed than the old Bafangs. The new ones might be better. The last thing you want when putting a bike in your car is oil dripping everywhere.
I'm going to build a 15S pack from 4AH zippy cells. The motors are more than fine at 12S the way we ride and I think they're be okay at 15S/63 volts/KU63 controller capacitor maximum.
[you'll be sorry you responded, but your builds are so nice you really should post them here. At least in the "Creations" thread, but then again, I'm bias to Rocky Mountain bikes]
