Hi Adam,
Your SMT PCB's look good !!! Hope they test-out OK.
I'm glad to hear that the discretes are 0805's, anything smaller would be to hard to hand populate.
On the next version of the Revolt Controller it would be nice to have an output for BMS like "bigh" recommended. I have some info on a LifeP04 BMS/Controller interface that was supplied to me with some BMS PCB's that I purchased. If you, or anyone else wants information on a interface reference design for a BMS/Controller PM me and I can forward that information out. I can't post information here because the reference design is copywrited material.
I hope that the "DIY charger project" continues to complete the whole EV system !!!
Keep up the good work !!!
-Mark