Long time no update

So I had a long break away from this project, got side tracked on a lot of stuff. But I've cleaned up my workshop and have been back working on it with a view to getting it finished off.
I bought a 3 phase brushless bicycle motor as a test piece for getting everything working as far as electronics and firmware. It has integral hall sensors just like my motor will have so everything should transfer over fine. I have done some more analysis of the honda electronics and tested the high voltage/high current outputs when I drive them with a control signal, they worked as expected.
I completed my ECU firmware to the point where everything is functional, sent dummy signals to check the RPM and road speed functions work etc. The LCD all works as it should.
I finished off my electronics box on sunday, it now has everything in it apart from a fuse holder and a final +12volt power supply feed bulkhead connector. I found one mistake when completing the final wiring.
I now intend to run a test app on each microcontroller and test every input and output to check for errors or problems.

If all is well I might be able to try and run the test motor in 1-2 weeks. I can then optimize my motor drive firmware. It might have a lot of bugs in it so require a lot of debugging work, don't know at this point.

LCD screen and firmware

I've almost finished all the motor drive firmware, I only have the regen part of the motor firmware to write. I'm also about 50% of the way through the EV main control firmware for the vehicle and LCD screen, it gives me info like battery voltage, current, watt/hours used, watt/hours left, road speed, motor temperature etc.

Control box

Here is a pic of the control box I'm working on. It has the maple for motor control and an arduino for the main EV functions and driving the LCD screen on the dashboard.

Haven't posted in a while

Don't have a lot new, the xmas break slowed things down a bit and I got stuck going in circles trying to modify the microchip code. I did this for about 3 weeks. I've changed direction a little and decided to pursue using the leaflabs maple to run my motor. I found a labview app posted online for FOV motor control, it allowed me to write my own C code for the maple.
So far I have the main functions well along, I am spending time working out the useage scenarios that the motor controller will see and designing my software to handle them.

Hall sensors and motors

I've been working on adding the hall sensors to my motor, I'm putting six sensors in the back motor. I only expect to use 3 as per normal BLDC position feedback but I'm putting 3 more backup sensors in. I have heard they sometimes fail so this means if I do have a problem I can simply switch to the backup without having to teardown the motor to repair it.
I made 6 little pieces of fiberglass circuit board that fit snugly in the gaps in the motor stators, they have cutout pieces for the hall sensors, I'll glue the hall sensors to the fiberglass with polyester resin which I found out is used in the fabrication of the winding parts of AC induction motors. If it is suitable for this then it should be good for my motor too, its cheap and easy to use.
I stacked the motors together and took a photograph, I had to remove the plastic protection guard from the bottom motor as they would not fit with it in place.

I had my first quote back from one machine shop and I'm awaiting more, it will be 4-5 weeks before I actually have machined parts in my hands ready to assemble, so plenty of time to finish other tasks.

Drawings finished....

So finally after a couple of months my drawings are finished enough for quotes from machine shops. Since sending them out I found a couple of missing dims and one dim I had to change but these won't change the quotes themselves.
I have sent them out to places all over to try and get the best price. This can be risky in that I don't know the reputation of some of the places but I'm hopeful it will work out ok.
It will take a couple more weeks to decide on a shop and once I give the go ahead a few more weeks at least waiting for parts to be finished.
I have other work to do while I'm waiting, embedding hall and temp sensors in the stators and prepping other parts. I've also been looking around for some old used car batteries cheap to test my electronics out, its proven to be difficult as even old virtually dead batteries have value for recycling.

Thanks to Tom Staub at High Plains Tool and Mold

My local machine shop didn't have the right tools to measure the stator dowel hole locations properly; so after some searching I found a website where some guys built a Honda Insight with a Tdi lupo engine. They had an adapter plate machined and so must have measured the dimensions I required.
Tom Staub at High Plains Tool and Mold (ph: 303-806-0451, 3201 S Zuni St # C Sheridan, CO 80110-1996) was happy to help and went to the trouble of finding his notes on the adapter plate. Thanks Tom!
Now I can proceed with finishing my drawings.