[reiderM]

If you can fit 16 modules, then you should be using a Tesla drive unit. More efficient and more powerful than a low-voltage motor, plus then you just have series connections at the module level, which is more reliable.

16 modules, Tesla small drive unit, no gearbox (drive unit has an integrated differential), no onboard charger (weight reduction). DC fast charging is actually simpler on the vehicle side as all the high voltage AC/DC conversion circuitry is handled by the fast charging station.

You could probably get 400 miles of range with such a setup. Possibly more.

 

[reiderM]

Thank you brian_
The hyper 9 is just easy available here. There is also a watercooled option.

We will take a look at the leaf motor specs and availability here.

Is it doable to couple several Original battery packs together? Say 2x 40kw leaf batteries. Does this require a special controller?

Leaf batteries have heat dissipation problems, they're just passively cooled. You'll run into problems if you try to charge them up quickly (DC fast charging). Leaf motors are good though. Leaf motor and tesla modules is a range-maximizing combination. Leaf motors are also cheap and simple.

 

[reiderM]

Do we need a separate controller?

For the motor/inverter (both are packaged as a single unit), yes. As brian said, there's the external CAN option. Or you can replace the logic board inside of it. There's loads of choices out there at a variety of price points to control a Tesla drive unit.

For the battery, you of course should have a BMS. Tesla modules pair nice with the SimpBMS (which I conveniently sell! lol)

I didn't get the impression that high power is required. Carrying more motor than needed and more battery than needed is a weight and therefore efficiency issue.

Batteries are certainly a case of diminishing returns as you add more, since it's also added weight. But batteries will store more energy than is needed to negate the added weight, so more is better from purely that perspective. If money and space is not a concern, of course. But yes, in terms of miles/kWh, you will definitely lose efficiency by adding more batteries. Keep in mind that more batteries will increase charging time, assuming that charge rate is held constant.