[cujet]

In the case of the gem car, he was running a bigger battery setup, a more powerful motor and controller. The nominal voltage was 120, so simply taking each 120V leg and rectifying it to DC would give enough voltage (maybe 150 or so) to charge the batts without any form of "charger". Setup an electronic (or manual, rheostat adjustable) regulator that limited generator output to some "adjustable" level that worked (say, 135-140v downstream of the bridge) and it would be self regulating enough to work while driving.

Not much to a system like that. Just a full wave bridge and a commercially available generator voltage regulator.

Remember, the DIY regulator would limit voltage to the rotor (armature) of the 115-115-220 genset, in my example. So, both 115V legs would be at the same voltage if under the same load.

Your genset could be different and I am unfamiliar with it.