Plus

@cheesej Great work getting that fixed! Surprised that damage was enough to break the inductor.
Thanks for sharing your process :)

@cheesej Hiya :) That's a 270uH power inductor. If there's actual damage to the windings on it that could cause issues.

The only time I've seen similar when the battery was fine is dodgy caps on the balance IC.
Cell voltages can report incorrectly if any of the caps around the balance chip at the other end of the pcb are slightly detached or faulty. Common to do when unplugging the XT60 and bumping one.

Might be worth giving this post a lookover to see if your board is doing similar if the inductor doesn't solve the issue.
https://owforum.co.uk/topic/403/xr-overcharged-cell-that-isn-t-after-battery-upgrade-repaired

@onedangts-xl The tire size increase was a must on the GT side. I mean the frame itself looks so much better now with the larger tire.

Speaking of, how is the tire?

At Opensauce the GTXS and XS got up to some shenanigans. The Friday afterparty comprised mostly of it and Wren's VESC showing off.

During the Friday setup I was asked to help Ivan Miranda repair his " wheeled Onewheel. I assume he'll have a video on that project at some point. However after we got it working I took a few chances to get a few pics with it.

Future Motion's Alec came to visit us and left his XRC with us while he checked out the rest so we used it as an opportunity to show the scale.

SimpleFOC's robot dog came to visit again and we handed over a little award for riding the first one.

Not long after we set off to Santa Cruz and spent some time with FM. We were only in the lobby this time which unknown to us meant there were some GT XLs around the place. Regardless we had some fun helping film some silly promotional clips and showing the team the little boards again.

We hadn't finished our little trip to Cali yet though. The next day we shot up to Sacramento to visit TFL. Sadly as we pulled up Jeff was leaving as he was ill but the rest of the gang were stoked to see it. Nico especially who after tweaking some of my settings managed to ride it. I have yet to upload the videos of that yet so just trust me bro™

Sadly the video for the above was deleted and nobody knows where it went or how to recover it but TFL did a really funny sketch about Nico handing over a regular sized board to Keaton who then holds the XS.

Some work needed doing for the charger so I got some parts made up and painted.

Tuning the GTXS was a bit of a challenge. I know a bit more about it since rawdogging the XS with just vanilla VESC so with Refloat installed I was able to get it to a near Apex-like tune. And as an added bonus... this

To get the right look for the rails I did some testing with the plastic ones and found I could get away with some resin printed stencils BUT the XS Series decal was way too fine to get spray paint down reliably so one of Nick's friends managed to make a sticker the right size and that worked out for it. The rest are painted on top of a light coating on the anodised rails.

Inside there's a USB PD trigger to request 20v. This then goes to a CC/CV boost converter set to charge a little over a regular 7s setup at 1A. I went a little over to account for the voltage drop from a reverse polarity diode I added that also protects the charge port from exposing Batt+. Even with a cover over the magnetic port I wasn't keen on leaving that exposed.

With the metal parts the build was getting heavy. Without it all together we were already at 3.2kg. Despite this it was able to bonk a little. Sadly the footage I have of this is hella low res for some reason. However it was enough to get a repost on stories from Bohdi on Insta so that's pretty dope.

With a few final touches and accessories to bring with we had it all good enough to bring to Opensauce.

I'll try keep this short 😅

Tire was moulded using a 2 part silicone mould with 3d printed inner and outer casings to assist in registration and demoulding. The silicone was made like last time by printing a master with a 0.2mm nozzle at 0.06mm layer height. This was filled and sanded to get an even smoother finish.

That resulted in this majestic bit of rubber

Shortly after I took delivery of the CNC, 3DP and new PCBs from JLC and they looked amazing! Cost about £1k after shipping and taxes buuuuut... like look at how good these came out.

Around this time I also got a thermal camera that I started sanity checking my work. Surprisingly the hottest parts were the 5v buck converter and STM32 package. The FETs even under load and DRV chip were chilling. Likely due to the thermal considerations I took but still they barely got warm. Being Pint FETs I guess it makes sense.

@lia I would love a short one, and maybe a few still pictures of the final product. The rails look so good, how did you do it? Is it paint, decal, wrap, ...? Did FM say anything about it being powered by VESC, or was everyone happy just to sweep that under the rug and enjoy your engineering skills?

Thanks guys! They really loved this one. Alec from FM came to find us at Opensauce 2025 and we arranged another visit to HQ. Also swung by TFL the day after ^-^

Kinda forgot to share the progress here. Does anyone want me to do a condensed update from the last update to now or nah?

@tribacon D4 is a diode to stop voltage being present at the charger when the board is powered on. Without this it won't charge.
https://www.vishay.com/docs/89000/ss10ph10.pdf