ok a bit slower than promised but I finally got to finishing the PFC stage for the charger! (if you are wondering why took longer than expected, check http://www.diyelectriccar.com/forums...ock-60262.html
Total parts cost ~$130 if you get them in bulk - including a used 200A half-bridge IGBT module from ebay. Of course, if you use this PFC stage with the charger, you are saving input bridge and at least one elcap that you now don't need for the voltage doubling. So technically net parts cost is probably around $100.
Tested to ~5kW so far. Waveforms are pretty clean - I am only limited by the heatsink at the moment as this thing does generate a bit of heat and my minuscule fanless heatsink just doesn't cut it ;-)
Recap of some parameters:
1. IR1153 PFC chip with overcurrent, overvoltage, undervoltage, etc protections. Switching at 22kHz - ideal for IGBT. Custom PCB
2. Same IGBT driver design as in the main charger unit - on a new custom PCB mounted directly on IGBT leads
3. 400uH inductor - same type as in the main charger unit.
4. In a half-bridge module I am using (200A 600V), one IGBT is used as switch, another one has G-E shorted to serve as freewheel diode. That way, stray inductances are minimized and thermal management is simplified. None of that stupid cathode-to-heatsink electrical connection to deal with in all the 'normal' power diodes...
Will post schematics and PCB files to the site soon - I'd imagine we'll add this to our kit options.