Step 25: Work out the kinks. Smoke escaped from the old PMC controller. 5 of its 8 power transistors are blown. I suspect some had blown early in test driving. It still operates the remaining 3 switches, but alone they can't provide enough current to push the car. I will try to repair it but in the interest of getting on the road it will be replaced with a Curtis 1231c. This has a higher current limit of 500A and a silent switching frequency.
The Curtis 1231c is widely used and requires a heatsink. I found one online and bolted it to the bottom using thermal grease. I borrowed the fan from the old PMC and mounted it on the back. There is good airflow out the end.