While I have enough prismatic cells to make a 36v pack, ea are 30ah so bulky. I ended up making a 27v x 30ah pack that worked out fine except with regards to a controller; 24v would cutoff a bit early (but in retrospect, and I'm not great figuring this stuff out but seems cutoff would be 2.7v instead of my bms' which actually is lower than I like a 2v.) Originally I burned a couple controllers out, but maybe that was due to my faulty wiring as I had just started my e-bike project and was all new to me.
So, forward 3 years later, while I had built it to do 15 mile straight country runs, very little stop and go, charge before coming back, I stopped doing that and have been using it for in town rides, max 3 miles but a lot of stop and go. Motor pulls 35a dead stop, 15-20a while accelerating and evens out at 10a. Lately I've started hearing a rattling sound that I've been advised and agree is most likely a detached magnet/s. Do you think this would have happened anyway, or is the sudden hit of 35a having an adverse effect? I use 2 toggle switches; one by handlebars to turn on or off as I ride, and a second one in rear to shut power down (also as a backup if front toggle ever stopped working, I can reach back and turn off master switch.) Thanks.