For Michael's tests, Here's the current data for AC Test 2. This had a current magnitude of 311 amps!! (220amp peak for Id and Iq):
AC Test 1 curents seem to track OK too:
Do you know where in graphs the regen quits? Could the sudden cutting out of regen when you hit zero RPM be the problem? Or could the throttle be hitting weird skipping spots? I don't see anything weird in the above graphs.