C-Bag: I've always used CRC products for board and contacts. Amazon and even HFT has them now...environmentally safe too.I wonder if anybody has any insight into using spray electrical cleaner to clean off the boards on my old controller that was working when I bought my mill?
Jere: Glad your RC is doing better! Takes a while (done both of mine a couple of times now) and was taught by a rehab guy to use 5lb dumbbells and raise them slowly from the sides to horizontal then down again, then up at about 45º in front, down, then up straight out then down again...rinse repeat for about 10 or more reps...as much as you can stand...then rest them at least 2-3 hrs. Couple of times a day and works for me in a week or so to be back to the grind or bandsaw...in your case.
Looks good so far on your build but still recommend going to Lithium White Grease on the gears...then the seal isn't as critical and less likely to seep into the motor.
Have you bench run your new motor with the controller? Thinking I might leave that transformer/coil in there to clean the pulses. Power is Power (1hp=~750W), AC or DC...to me it's the torque associated for all the drive mechanisms and what's available in Amps from the controller that's available to windings/frame size of the motor. The controller quality/match to the motor is Key for your application. Theoretically based on what you've shown here it should be better than the original 1/2HP motor by a good margin. Look forward to your progress!! ~PJI would rather have as much power as I can get with the bandsaw. they are considered underpowered with 1/2 hp motors the saws came with.

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) and was taught by a rehab guy to use 5lb dumbbells and raise them slowly from the sides to horizontal then down again, then up at about 45º in front, down, then up straight out then down again...rinse repeat for about 10 or more reps...as much as you can stand...then rest them at least 2-3 hrs. Couple of times a day and works for me in a week or so to be back to the grind or bandsaw...in your case. 
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