Have you run yours for long periods of time at 45a and 60-100v ?
I still haven't gotten around to drilling the other side holes yet, but every time I've taken it for a hardish ride lately it's come back too hot to keep your hand on and the motor smells hot. I've dialed it back to 35a for the time being but even so with my 25 minute commute to work it's pulling 30 amps probably 75% of that time and is still pretty toasty when I get there. I upgraded the stock connectors on my 12ga phase wires to 4mm bullets and while I wouldn't have expected it to make much difference (I didnt feel any) I was keeping up with all the traffic today in 70km/hr zones so either everyone was driving slow or it's gotten a little faster since my last GPS run. I'll take my GPS tomorrow and track my ride work and see what it shows.
I have another problem in the mean time, I've managed to lose 2 spokes. By lose, I mean they've pulled out of the nipples and basically fallen out. A few of the other nipples were loose with alot of thread showing and I've hand tightened them up for now which has made them alot better, but I suspect I'm going to have to get the motor relaced, probably into another rim. I think it's largely bad QC on the part of GM, some spokes are slightly loose with no room for further adjustment and others are showing heaps of thread with no the nipples just barely hanging on. The bad thing is the 2 spokes that pulled out had the nipples disappear into the rim. Being deep V style double wall rims It'll be almost impossible to get them out so for the mean time when pushing the bike along or rolling at very slow speeds you can hear then rattling around in there like loose change in a clothes dryer
I guess there's a risk of them puncturing the tube, but while ever they're inside the rim I guess they wont. You watch me have a blow out tomorrow after saying that
The plus side is they're directly opposite each other so I dunno if that makes them balance each other out, but there's no noticable wobble in the wheel and it feel solid enough so I'll keep riding it to work for now I guess. Hopefully I don't have a catastrophic failure and go under a truck at 70 km/hr...
In other news I made up my PVC lipo box.
This is the 6 6S 5ah 25C zippies I'm using, layed out in their configuration ready to be put into the 100x50mm PVC. When I say put, I mean jammed like there's no tomorrow! What a task it was getting the batteries, 10 gauge wires and the balance taps wires and connectors to all fit.
I then cut diagonal slots in the corners of the PVC, heated it up and folder them over. I then filled it full of bog (bondo)and painted the end of it in charcoal hammertone. I was originally going to paint the whole box but with the bike being while it actually matches keeping it as is. I've also added a "key" of sorts in the end, it's just a spare 4mm bullet connector set into the bog that A: disables the battery when removed and B: breaks the circuit with the turnigy watt meter, this saving power when not in use.
I also stuck on the high voltage sticker for kicks, and it breaks up between the while and the black. I might put one down eahc side of the box later too. I hunted around but couldn't find any that said "caution: KFF inside"
I don't have a 75v power supply sorted at the moment so I've soldered the balance taps and discharge leads together to create 3 lots of 6S2P and bought each pair of wires down to the back of the back and have it terminated with 3 lots of Andersons. The plug connected to the controller adds all 3 batteries for 18S discharge and the charger plug charges up to 4P. My other battery pack charges this way, this one is only 3P but that's not an issue.
And this is how it looks at the moment. The controller is still ghetto'd on with a piece of old inner tube but I'll mount that properly and tidy up the wiring once I sort what sort of current limit I'm going to run and a neat way of switching it. It's not super stealthy but it doesn't have a massive rack on the back that sticks out like dogs balls either. I prefer it neatly on top like that instead of the batteries all stuck at funny angles inside the frame and because of the low stand over height of the dirt jumper there's still miles of clearance when I step down off the seat.