Don,
Sorry to bug you again, but not much has been said about your Cougar controller and power PCBs. Those Rev.D files have been on the Wiki for months.
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The extra functions are:
1. Motor Speed Sensor
2. Battery Voltage Monitor
3. A 2nd mosfet driver to drive a 12v load
4. Configurable Input A/D or opto isolated digital
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Are you using the 2nd mosfet drive to switch the Solid State relay for your Capacitor pre-charger? And the opto isolated digital output for your 150A 12V relay to switch your case cooling fans?
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The power board is 4 oz copper. Where the Cu is thinnest between the diodes and mosfets there is no solder mask and I run a thick bead of solder to improve the current carrying capacity.
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How are you attaching your busbars to your Power PCB. Are you using silver epoxy like Paul, or are you soldering them to the PCB. Your websites optional service states "We will tin all 3 bus bars & sweat them onto your power board." How are you doing that? Are you reflowing solder paste to attach the busbars and PCB
Looking forward to your comments!!!
Thanks,
-Mark