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If you cheap out on the DC/DC, it will cost you. I know a guy who has burned out so many cheap dc/dc units that they collectively have equalled the cost of one high quality unit.
Here is a gentleman in my state who is getting respectable numbers from a forklift motor in a Gen 1 Saturn SC (keep in mind this is a very light car. The body panels can be weighed in ounces :P )
He appears to have found a 72 VDC forklift motor. These are not easy to find, but I think you will be much better off if you take the time to look for one. Plus, with a 72 VDC motor, you can add cooling and over volt it to 84 or 96 VDC for a noticeable increase in power and range. This may require tweaking the brushes (do your homework).
Remember, to keep things economical you can build Paul's Open Revolt controller.
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Hehehe... If one of your facial lacerations leaves a small scar, you'll have a SCarlett.
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