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Most awesome work on this project!
I agree with Phantom, that an automation of the motor/ generator would be a huge help. Once you fully electrically and mechanically integrate the systems, your efficiencies will jump.
Do you have an amp meter on the motor wiring for both in and out (throttle and generator modes)? What type of volts/ amps are coming off during regen mode?
Have you thought of deleting your alternator and pulling a 12V string from the motor during regen mode? You'd probably need to add another AGM to replace your OEM battery to get more AH, and some onboard solar connected to it to help extend range. It seems like the standard alternator is just in the way if you already have a larger generator source on board, plus its fighting the motor when it engages (rectifier turns on and causes mechanical resistance when your battery needs juice).
You could pull a string wired to engage during regen, drop it to 12v, run it into a charge controller with the solar and then to the 12v.
Again, many props, most impressive!
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