I did a check to compare the copper fill with different wires.
From left to right slot in picture, absolute max theoretic figures below.
Round wire dia 1.5mm:
58 turns per tooth, pi*1.5^2/4*58*2/267= 77%
Square wire 2.5x1.25:
32turns per tooth, 32*2.81597*2/267= 67%
bundled wire 7x1mm dia:
28 turns total 28*7*pi*1^2*4= 58%
Single round wire will be the best for fill in theory. But i doubt it's possible to route six layers well without many crossings and it gives an absurdly low kV.
Using the 7x1mm bundled wire in a single layer/LRK wind is attractive since it's a lot less work and gives a higher kV.
28(turns)*6(slots) is only 168 turns in total vs 30*12=360 turns to wind for the square wire/double layer. The smaller wires should also be better for eddy losses.
The dual LRK / dual controller setup let's me double the controller power available and gives me some redundancy at the cost of a lot of added complexity. And it's fun
(but my battery will not keep up
I am leaning towards trying the double LRK with 30 turns of the square wire, 63% fill. That's 7% higher than in the previous wind so it might not be doable since its 10 wires extra in the slot compared to previous wind. I'll cut the wires for 30 turns and see, it can always be cut shorter later on.