[QUOTE=Firedog91902;21478402]Powell,

. One I forgot to mention is regen braking issues. Since the charge boards think the SOC is always near zero, regen engages even if the batteries are full (40V).
QUOTE

Firedog,
I am fully aware of this issue , really - upper processing board stores real SOC of battery , displayed SOC is based on Columb discharge count by main PIC processor PIC16.
since in my conversion charge is done OUTSIDE lower power board /outside EPLUS electronics/ of course PIC16 doesnt know battery is charged and still thinks and displays empty on display/contr.
As a result PIC 16 allows for regen right away.
the thing is
for my Chevy Volt cells EPLUS regen current activated by brake lever is very, very low, unless you use REGEN level 9 maybe, but who would do it right at the begining or ride?
anyway - Cycle Analyst on my EPLUS shows max. -500W returned to battery when I sqeeze break lever , so 500W divided by 43V is ONLY : 11.6 Amps. - really nothing for Chevy Volt cells.
but
I charge to max, max 90%SOC and as I said EPLUS regen current is like nothing for Chevy Volt cells.
If you use tool batteries that is completely different story.
I never noticed any jerk from EPLUS motor bigger than when battery is say 50% depleted.
jerk is exactely same at the beggining of the ride and when battery depleted.