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I still think it's maxed out on winding speed.

Very strange, what is more important for me is to see some nice big disks on a diy conversion!

Depends entirely on the winding speed. If you are building a motor with 50Nm of torque when you know the top speed is restricted to 15mph why would you wind it any faster? Suntour have a 28mph 48V motor called E45 for faster bikes.

Could be that the motor winding speed has maxed out. Use a gps speedo (phone) to check your speed, see if its slightly faster with a fully charged battery. Could also be that the hall sensors give the speed information to the controller and your sensor wire is only for speed display.

No he didn't he said it was like that after 10 meters, i.e. just enough time for the motor to kick in and spin out of the dropouts!

I have and it is absolutely clear that the pictures are after he has ridden it even if only for 10 meters. The fault is NOTHING to do with brakes, if you can fit an axle without rotating it to the correct position the dropouts are already shot.

I'm not disagreeing with your post, your point 1 is probably the cause.

When are you going to realise the pictures are showing the wheel AFTER it has rotated in (out of) the dropouts and stop with the irrelevant coments about the brakes. Torque washers are not a solution for the worst case, they merely give the axle flats someting to locate on that doesn't have an...

New legs required ;)

I actually normally ride at a higher heart rate on the ebike, knowing I can just turn the assist up and cruise up my final 17% climb home if I need to.

Why does the EU get the blame for everything?

It's got NOTHING to do with the brake disc! The brake disc has not been replaced. Yes there is plenty of room for the disc to go into the caliper on the picture. I suspect the mag disc was the pas disc, it certainly wasn't the brake disc.

The axle was seated, it has turned itself out of the dropouts due to the motor torque. What you are looking at is the after effects of that not how it was reurned.

And wear brakes out quicker.

Don't quite know what todays posts are on about. The pictures clearly show an axle (not axis) that has rotated and pulled the wheel out of the dropouts. The guy in the shop didn't send it out like that. He did not understand how the wheel should be fitted i.e. with torque washers or arms and...

How many people have actually broken chains? The only broken chains I know of are when someone has messed up when fitting it and left it too short. Even with a legal mid motor I doubt it is an issue as it is no more power than pro cyclists. I think damaging the rear mech off road is far more likely.

Don't think spares are available. As far as I know any faults inside the motor require a new motor or if outside the warranty the tools and skills to diagnose and repair what is in there.

Cleaned them with what? Cleaning pads is a waste of time, get new ones. Whatever is contaminating them will have soaked in, you may remove some of it but in time the contaminant will leech out again. Agree with Nealh brakes don't need bleeding unless they have boiled (unlikely) or been opened...

Really, please do explain why. Series I can understand but when paralleled it makes no difference what the capacity is as the load just sees it as 1 source. Of course the voltages need to be matched before connection.

I use the bag mentioned in this thread http://www.pedelecs.co.uk/forum/threads/homemade-battery-idea-for-a-bag.31117/ to carry 10s3p (36v) Im sure it could take another 9 cells or you could run 13s2p to make it a bit lighter with reduced range.