Going Into Storage
This project was started way back in 2007.
It's great to have gotten it running, but I bought an undersized Kelly Controller that seems to be faltering already. The specification suggests a maximum of 40 amps continuous and I've been running 50 amps and on regen the voltage spikes above the controllers limits too. Now the controller cuts out all the time. What's worse is the PC to USB interface has failed completely. I no longer get any power in the USB and the RS232 cable was getting warm while I was trying to use it. (so something got fried). In a sense the controller is "bricked". The ebike only runs when the battery voltage is on the low side. A full battery almost instantly triggers overheating.
Ideally I need to upgrade to:
KDS72200,200A,24V-72V, Mini Brushed Controller
Peak Current, 1 minute: 200A
Continuous current: 80A
Complete the RC motor upgrade that I gave up on and then switch to a brushless controller.
Go back to the low tech chinese controllers that are durable, but lack programmability.
Search for other controllers.
Increase voltage to make the bike capable of higher speeds. (this becomes possible with the 72 volt upgraded controller)
For now I'm satisfied with taking a break for a while.