Despite the issues with the car, I've decided to start commuting 15 miles each way to work to see how the car does. By not revving the motor above 5000RPM, I can minimize the vibration problem.
The batteries are starting to break in. I'm getting slightly more power on the freeway now and starting from a dead stop is acceptable. I've taken the 914 up to 70mph. It doesn't have the pep that the original 2.0 liter engine had, but I still haven't really cranked up the AC controller and done a parameter analysis.
The car wobbles at 60mph with a low-frequency side-to-side shaking, so I took it into Les Schwab this morning and they found one of the back tires to be significantly out of balance. I'll take it back up to 60mph on the trip home.
In general, I'm pleased with the freeway performance. Although, if I put the car under heavy acceleration for a long period of time, the batteries "brown-out" down to 128V or so and the controller cuts back the power significantly as the voltage drops. Letting up on the accelerator allows the battery voltage to come back up and power comes back. I could adjust the parameter in the AC controller to set the voltage cutoff lower, but I fear damaging the batteries.
I looked at installing the PakTrakr battery monitoring system last weekend; however, the wiring distance between the front and back of the car is longer than the provided cables. Ken Hall (makes PakTrakr) said that I could extend the cables as far as necessary, so I grabbed some 4-wire cable and will be extending things soon.
I've given several people at work rides to show them the technology and everyone has been very supportive.
Next up: More commuting and checking out PakTrakr