Oooh... Brutal. That's some seriously cringeworthy disassembly/soldering. Sorry you had such bad luck taking your controller apart. An expensive mistake, though I suppose that's how you learn.
Noq said:
*looks at your thread*
Wait. With the Leaf batteries, your CA says "Amax 354.4". Is that... are you kidding me? Did you hit that? (Then again your Amin says negative 46.5, so who knows WTF.)
I'm going to go out on a limb and say yeah, that's probably correct. The negative amperage reading is probably because regen. That's complete and total overkill though, that's like 30kW peak output, which is probably enough for a small car. I've no doubt mistercrash could drive his new bike up a vertical wall with that much torque.
I ended up upgrading my motorino XPD with 4x leaf modules (60V) and a Kelly KEB72301X controller. The controller is rated up to 150A but I rarely set it above 60%, so 90A peak, and that's plenty enough torque for me. I can reach full speed within 5 seconds or so, and hills don't slow me down at all unless they're especially steep.
At a full charge of 67V, my max speed is around 55kmph, which is enough that if I went any faster I'd be really concerned about getting pulled over. I wouldn't want to up the voltage to 72v unless I had some way to register and insure it as a LSM.
The leaf modules *almost* fit in a motorino's battery box. I had to use a sawzall to remove the box and move it back an inch to get everything to fit, but in the end it was worth it. I LOVE these leaf cells. They keep really balanced, they have a small number of high capacity cells so you're not fiddling with soldering/spot welding hundreds of tabs. I've been using this battery without a BMS, just a bulk charger, for over a year now, and the most I've seen them out of balance was like ~0.05v
Anyway, one thing to point out is if you're going to replace your controller with anything but the motorino one, you'll lose your dashboard. I ended up welding a smartphone holder to my handlebars so I use an old cellphone for a speedometer, and a voltmeter to measure the battery. You'll have to come up with something similar and factor that into your costs as well.