This is more of a question, specifically aimed at Thingstodo or anyone with lots of electric motor experience.
This question really digs to the heart of this thread - IE the "hotrodding" part.
Specifilcally, I consider "hotrodding" any time a person modifies a device and strives to gain performance out of the device they are modifying.
Frequently, the modifications are improvements to the original OE design where one substitutes higher quality or more effective parts for the (most likely less expensive) OE options. Look through any Summit Racing or JEG's catalog - you'll see what I mean.
After the mods suggested by Freebeard - modifying the geartrain for less friction and higher stress capability - I think we should consider the cooling system.
Most electric motors are rated at some power output, primarily based on the ability to reject heat. Whether the motor is supposed to run continuous or intermittant duty has a lot to do with that. The ability of the motor to absorb the heat, or thermal mass, has a lot to do with that consideration.
Toyota puts a limitation of 50kW on this motor; it would be interesting to figure out how they reached that number, and how far one could push past it. Because there is no external heat rejecting device (radiator) the case of the MGR must be able to dump more than 50kW - the motor's waste heat in addition to the gear and bearing inefficiency.
Ok, after that long introduction, Thingstodo - do you have any way of calculating the maximum current one could subject the stator to? I know you did that test on a copper wire - that was extremely interesting. I **sort of** have the winding specifics - we may be able to figure out the maximum current for a short time.
Seriously, a short time like 10 seconds (with adequate cooling) could allow a radically different amount of current (thus power).
Also, I think the stator coils are cooled by oil spraying up through the rotor - I need to verify this. Looking at the cutaway, perhaps there's another (additional) way to cool the stator? This assumes that the method of cooling the lubricating oil has already been taken to it's highest potential.
Suggestions of where to start looking?
Thanks a bunch,
E*clipse