freebeard
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Sounds to me like the trade-off is thinner wires with thicker insulation.
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That seems to be much of it, at least for the full voltage wires. Still need to figure out the insulation rating on the actual motor windings, though.
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What vehicle is the 'one-off custom'? An FJ40? You could use two single-speed MGR instead of over-stressing one.
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Yes, an FJ-40. I'm looking at using a Leaf motor because it will do 80kw continuous, based on ARNL(?) testing showing that rotor temperature seems to top out at 135C when driven at 7,000rpm at that power level. If it turns out that the high voltage is just is too much hassle, I may go the two-parallel-systems approach. That means two motors, but I'm not trying to run double the current through a stock motor. Maybe one of the "brain replacement" projects for OEM inverters will be available by the time I can do this build, which will lower the overall cost a bit.
I'm sticking with a transfercase and gearbox at the moment. Motors aren't quite there yet in power-density plus speed range for me to stick 1 per corner or 1 per axle and still have both rock-climbing ability and freeway speed capability without changing gears. With 35" tires, I need 576 RPM at 20kw continuous per wheel to do 60mph. To climb rock walls, I need 3250 ft-lbs per wheel (assumes full 6500 ft-lbs driveline torque in 1st-low with stock engine/gearing, and 2 tires in contact with the obstacle being climbed). Gimme a motor that can do that, at less than 100lbs per motor, and less than $2000 per motor/inverter set, and I'll seriously consider wires and cooling lines instead of driveshafts.