It is getting hot this summer. The AC is working like a champ. I've run out of charge a handful of times over the past 6 years. Each time it was due to my charger turning Off due to high temperature. The model I have appears to need to be reset to recover from this condition. However, if I don't pay attention I do not notice that I'm heading out with less than full charge.
I picked up a Manzanita Micro PFC20 charger with forced air cooling. It's the green box at the bottom of this picture. The previous charger only had fins for cooling.
Sure enough, this charger overheats as well. At least it continues to charge, only at a lower rate. The BMS is wired to give it the Off signal when charge is complete. This charger will half my charge time, in the winter at least. 1 hour of charge per ~12 miles.
My water cooled motor controller is overheating as well. I may need a bigger radiator.
My battery has been at 120 degF by the time I get home from work lately.
I'm now on my 5th flex disc in just under 6 years. The Meyle brand lasted almost 1 year. That's an improvement from the last candidate. Again I'm switching brands, finding one that is slightly more expensive this time.
I'm beginning to believe the issue is the high starting torque of the DC motor. I don't use 1st gear because it is very jumpy. I start out in 2nd gear and usually nail it.
I can tell the unit goes under a lot of force. The grade 5 bolts in the pic below were new 1 year ago. Notice how a shoulder has been worn on the ones at the bottom. I lost the 8th bolt on a turn, that's how I knew it was time to swap a new one in.
My driver's side mirror fell off underway. I was able to turn around and retrieve it. The part that it holds onto the door with had worn away and no longer provided a purchase.
I fabricated a replacement for this part in aluminum and made a gasket from inner-tube.