A good friend of mine, Bill French has some musings on building his own motor controller:
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The expensive part is knowing how to build a controller. There are several open source projects out there, that's how i got started. For probably $60 in parts my controller can do 48V and i've measured pulling 280A through it. But .. it doesn't have brakes, regen... and i've had to take a sawzall to it twice mid race.
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Just as an addendum, the reason he had to take a sawzall to it was one of the Mosfets on it had failed in the closed condition resulting in a motor stuck spinning at full throttle forward.... better be quick with the e stop. The sawzall was to cut the burnt up mosfet off the board in an expedient fashion in order to get back on the track more quickly.