"/Ok, new thread.  What is the ideal regen?/" 

I think the Curtis controllers permit a good approach.  You can have regen
off the accelerator pedal, and the software permits you to limit how much as
a function of motor rpm.  You can also have regen off the brake pedal, using
similar "brake map" parameters.  HPEVS sets up their vehicles with both,
moderate regen with accelerator, aggressive regen with hard braking.  Seems
like a nice way to set it up.  Of course regen current is limited to prevent
battery pack voltage from exceeding the User_Overvoltage level set in the
software.  I have this set at 124.8V in my car, 3.47V/cell.  I've only had
it trigger a couple times.  If I am as little as 5Ah (97% SoC) below full
charge it does not trigger, even on a fairly aggressive deceleration.

Also, I use the full 5V of my Hall throttle.  You can set it up to define
about any voltage as full throttle.  If you set it at say 3V, then the
throttle is more touchy - more like some ice vehicles where if you just
touch the throttle the car jumps.  If set up this way you will have a
difficult time holding regen at 0% to coast, and you will over and
undershoot while driving so that you slow a bit more than you wanted,
accelerate a bit more than you wanted, then have to correct.  This of course
results in somewhat lower efficiency. Using the full 5V I don't have this
issue, but the pedal would likely feel a bit mushy to someone used to an
ice, since you have to press it a bit further to get a typical acceleration
rate.



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