That Cougar board looks very nice, I have one on order.
James's ac controller looks even better! My next ev will definitely be ac powered, but got to get this one finished and reliable first. Maybe the price will have come down a bit by the time I want one......
edit: It works!
Have just now powered up my rebuilt controller, running from my 35V bench power supply (with the primary regulator fiddled so it'll work down to this voltage - normally needs over 100V). I have a couple of 12V quartz halogen lamps connected in series for a dummy load. Throttle pot varies the brightness very nicely. Now to fiddle with things like the thermistor input and maybe play around with the drive resistors.
Here's the gate drive waveform (top trace) and the resultant load waveform. The thing is drawing just 1 amp from the supply. I'm wondering why the load waveform has such rounded corners? I stuck a 100 ohm resistor across one gate drive resistor and it sharpened up the falling edge corner very noticeably. Also, shorting out the thermistor input dropped the drive frequency from 13.6 kHz to 1 kHz. Not at all what I expected. The current drain from the power supply didn't change, nor did the lamp brightness by any appreciable amount.