If you wired up your controller using the 500Amp cougar mosfet schematic rev 2D that is found on the revomit wiki page--it has a serious labelling error on connector J5 from the controller board to the power board. J1 and J12 are incorrectly indicating their polarity and connection to the battery pack B+ and B-.
Is it at all possible that a failed mosfet or diode could be causing this?
Is it possible forr either of these failures to occur without knowing it?
Ive pulled in the pretty high 400 amps from my battery pack (according to my own external data logging equipment) on some of my recent hard accelerations so Idunno if that would be doable with a failed mosfet.
A failed mosfet would show itself by being a dead short, which would then blow the source leg clean off. If isolating the controller from the chassis makes the problem go away, there's no way it's just a failed mosfet or diode. So I think you are good there.