Well, it's not gonna get RPM tested just yet.
I blew up the controller.
I successfully soldered the wires back in place, (except I put the halls in same color order as phases just to make things easy on me later), reassembled the controller. Hooked it all up and got nothing. DMM showed only 1.4V on the hall power line, but 5V on throttle, so I figure I must've soldered the wire on the wrong pad or something.
Opened up the controller, and couldn't hold the DMM probes steady enough to guarantee not shorting anything out while I probed for another 5V pad, so I just pulled the hall power wire back out of hte case and spliced it into the throttle power line. Still read 5V, so I must've had the wrong pad. Dunno how...it looks like the same one it was on in pics earlier in this thread.
Anyway, fixed that, and was setting everything up to test it before putting the case back on, just in case I screwed up something ELSE. Hooked it all up, set the hall wires from motor in same color order as the hall wires from controller since now they shoudl work that way. Held the motor case a bit off the ground while resting the edge of the case on the mat, just so it will not end up twisting and ripping wires.
Powered up, normal current draw per WU, lightly squeezed throttle up and motor spins...then my previously-broken left hand (that has never healed right and has been hurting a lot since late last week) spikes pain and I lose my grip on the motor. I tighten my grip on the throttle without thinking, as I try to catch the motor, and it spins faster and twists the wires out of my hands.
That wouldn't have been a problem, if I hadn't A) not yet put the cover back on the controller, and B) left a pair of needlenose pliers about a foot from where I was working with the motor.
Naturally, the powered up controller PCB landed right on the only metal implement within several feet of it, resulting in an incredible show of sparks that scared every dog out of the room in about a tenth of a second. It took me several seconds to react, cuz I'm tired and my hand was really hurting at that moment, but i got the power disconnected, which stopped the sparking.
Results: Mat, pliers, and controller have interesting burn marks. At least one FET is shorted, cuz the motor is pretty hard to turn.
So...now I have to figure out what exactly is blown, and I have to hope it's only FETs--those I have spares of, and can physically work with. If it's something else, I'm not so sure I can fix it.
Crossposted to the controller thread, too.viewtopic.php?p=514878#p514878