Paul
That sounds great. I willalso keep in touch via e-mail. The answer to your question about reversing the supply is no. That could not happen as I have two packs of 60 v each so even if I did reverse the second pack there would only be zero volts across the controller. I drew a pic in corel and converted it to a PDF for you to see. Atteched also pics of the reverse side on the controllers control board. See the diodes there. I have no idea what they do either, and no, up until now I have never done any work on this controller other than mount it on a huge heat sink.
I have the contactor connected through a timer which connects the pre-charge resistor (49 ohm 10watt) for six seconds then it allows the contactor to engage when the accelerator pedal is pressed. It dis-connects when the accelerator is let up. I have read what Adam said and it sounds plausable to me. I will check the contacts out and report later.