I enjoyed reading through your build report. It's fun to see somebody else publishing them in this format. I have to admit when I heard about a bar direct driven off of a motor like that I expected the magnets and shaft to break on the first hit. After reading the build report I see that a lot of effort was put in to keeping those parts alive. It's awfully tough with that much energy going through them though... That bearing mount setup on the blade is some serious kinda project!
You mentioned problems with the Castle controller. I have been running Castle gear on my 30s for a while now and I like the beefy heatsink, data logging, and reliability I've had with them. I did blow the leads off of an ICE-100 one time when a belt jammed at spinup. I emailed the company to get the half-price replacement and they said "it shouldn't do that, we'll send you one for free". They've been pretty solid since then for me. The data logging has been really useful for motor/battery sizing.
I have also had the experience of scraping epoxy off of motor magnets with a screwdriver. It can be quite a pain if you get it in the wrong place when trying to lock the magnets in

. I hope you didn't get pinched when you were working with the magnets - they can be pretty strong in a motor that size.
I like how you start with "Wiring my Rum Ham XXX was a pain" and then later on "Zac's new FBS...glad I didn't have to wire this". When I read the first comment I thought "I feel your pain" and then hwen I got to the second one I laughed aloud.
Very cool stuff
-Zac