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I agree with Sebart that you should change the mosfet driver.
Sebart, 5th gear at 25mph I think would have a very heavy motor current requirement. The motor would be turning so slowly. I think that would be very hard on the controller. 2nd gear at 25mph would be safer. You want the motor spinning at like 3000-4000 rpm.
IGBTs have a long turnoff, so it's better to use negative voltage for turnoff with them. I'm not sure if you can use the board unchanged with them or not. The temperature probe is on the heat spreader. There's a short time delay before the temp sensor gets the memo that the mosfets/diodes are getting really hot. There are quite a few people that have contacted me that have put thousands of miles on their controllers, but I can't really figure out what went wrong from a long distance away, when it's a different power board design. My guess is that 5th gear at low speeds was really hard on it.
Nevyn, I wouldn't worry about the holes at all.
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