Assembly

Hello! OK, let's start with the PDF. The default is to use a hall effect throttle. You can use either needle nose pliers and a little dab of solder, or a proper crimping tool like this (there may be a cheap chinese equivalent, but I'm not sure): https://www.amazon.com/Engineer-PA-09-Micro-Connector-Crimpers/dp/B002AVVO7K

For the power section, I would suggest plugging in your board to 3 IGBT half bridges, and then placing the IGBTs/board on an aluminum plate and then mark the 12 IGBT holes. Then you can drill the 12 holes with a hand drill and once they are fixed, all you need to do is add a B+ and B- copper sheet that bolts to the 3 B+ and B- points on the IGBTs (see the PDF). I recommend making the copper sheets so the cross section is like this: ][. Then put an isolation between the 2 sheets. Something like Kapton tape, or nomex paper. So it would be like this: ]|[. ] would be B+, [ would be B-, and | would be the nomex paper or Kapton tape. The idea is to bolt on the capacitor(s) upside down to B+ and B- sheets, and also bolt the sheets to all 3 IGBT half bridges.

I would suggest these capacitors in terms of easiness to work with: http://www.mouser.com/ProductDetail/Kemet/C4DEFPQ6380A8TK/?qs=%2fha2pyFaduirlwqMzJdHObEtto18oyxlysT8gAtZWUnxAPJA0UHMcQ%3d%3d

3 will fit, but It all depends on what power requirement you have. Alternatively, I would get this: http://www.sbelectronics.com/product/700d348-power-ring/ It's more mechanically awkward, but is capable of higher power.

next, decide what current sensors you are going to use. What is the maximum current your motor will see? I recommend Lem Hass 50-s, 100-s, 200-s, 300-s, 400-s current sensors. Depending on the sort of current sensor and where you mount them, will determine how you will build your current sensor cables. I suggest 3 of them for extra safety.

The board needs +24v for power. To get that I would suggest this: http://www.mouser.com/ProductDetail/Mean-Well/SD-15A-24/?qs=sGAEpiMZZMvGsmoEFRKS8N2RkxUSJnDinUf%252b7ghl12k%3d

Then you can use the car's +12v auxiliary battery for powering the DC-DC, which in turn powers the board.

I'm putting together a video assembly, but it's not done. One possible assembly process is here (specifically designed around the 16 tab ring capacitor): http://www.instructables.com/id/200kW-AC-Motor-Controller-for-Electric-Car/