Rodgah - never be afraid to chime in! You have some great skills, I wish I could weld.
Well since my steep learning curve eventually got the motor to turn over (thanks again Steevil), I decided to retrace my steps and get back to my original plan.
I pulled the GNG off the frame and the controller, this will eventually get modified with the best of the mods once all the upgrade parts are available and then used for back to back comparison.
I re-installed the Recumpence Astro drive and controller and low and behold it spun up, once I bypassed the pre-charge resister, fancy that.
It spins really fast and I was amazed at the force it created for such a small motor. I spun it up half a dozen times with the wheel off the ground, sometimes it was a smooth ramp up, sometimes there was a rough sputter and stammer, it was smooth more than it stammered. I kind of figured there were going to be issues with a high RPM motor and a sensorless controller but had never seen the effect before, easing right off and then applying the throttle again seemed to get it spinning properly at least in no load test condition.
There will be test driving under Astro RC power today for the first time......
I took a couple of recent shots of how the fatter canopy looks, the big 48v switch is now gone for the moment, it was too visually obtrusive, but i might try to build it in later.
The left non drive side of the canopy has been fixed together as one piece, my idea is that this will be machine screwed on and be pretty permanent, it would have the breaker/switch and charge point fixed to it.
The right drive side canopy is still a 2 piece affair and will provide access for everything, it is only about 10 machine screws, so it is not a real hardship to remove.
The things to do list is long and includes the following, finish and paint the canopies after reducing the thickness to 3" at the controller (too wide between legs), relocate drive to bottom of frame for better chain line, add Burties Opto sensor and new sensored Lyen controller, add pedelec sensor, program 3 position switch and hide it, rebuild battery back to 20ah config with BMS, swap the Alfine rear wheel to the Rohloff once I kill it, finish making the fiber glass plug for the carbon fiber mud guards, lighten all metal parts where possible, swap out all stainless screws to titanium plus all the usual cleaning/polishing and fine tuning stuff. There is also the Jobe motor sat on my shelf that will at some point get fitted once everything else is sorted.