Seriously. It’s freakin’ solved after 4 years of research….

One of the boards that arrived for repair last week, was by far the worst I’ve
ever seen for dropouts, and it flashed the fault indicator in a very radical
fashion. It is now perfectly drivable!! No dropouts under acceleration or regen!
I was in total disbelief!! It works? Must be a mistake!! So I grabbed the second
board in for repair. Dropped out every 15-20 seconds. Made the same
modifications to it. Now it’s smooth as glass too! Zero dropouts under
acceleration or regen!! I had a third board laying around for years who’s only
crime was having massive repetitive dropouts. The modifications completely
stopped all traces of dropouts on it too. All 3 of these boards drive perfectly
now! Am I dreaming!!?? Feels like the Twilight Zone around here!!

Three boards saved from the junk pile. I have seen many more just like them.
That feels so good!! Many owners have this problem right now.

The Dolphin hardware has component values that are just barely within spec. With
miles of driving, time, and thermal cycles, the hardware goes out of spec, and
the Dolphin starts faulting, usually without any faults shown in Dolcom/Dol7.
I’ve posted this in the past. But the faults are felt as a sudden shudder in the
drive train. An instant loss and then instant return of power lasting only a
split second. It can rattle your fillings loose!! Some do it rapid fire, one
dropout after another. It’s all the same problem with the hardware going out of
spec. I found the faulty hardware!! Finally!!

During this research, I found an old quality control document from USE. It was a
long list of things that needed to be checked on their test fixture after each
board was assembled. The items on that list were very telling. So I have figured
out the procedure for checking most of the items on that list on my test
fixture. This ensures that the board gets thoroughly checked. I use it on every
board, just like the factory did.

Since it’s still very cold over most of the country, now is the best time to
have the offending boards with dropout issues repaired. The cold always makes
the dropouts worse. It’s the best season to ensure that the boards work in the
worst conditions of the year. Dropouts are less common in the warm months.

Send me your board and I’ll make the classic dropout modification and put your
board through the checkout list on my test fixture for $50 + shipping. Pack your
board very carefully, like it was your first born baby.

Mike