I completely agree..... voltage is a critical piece of information and the only thing you can completely trust. Before I even bought my first Zero I was already thinking about this problem with their design. My work around was installing a DVM to get voltage and using the Zero app for amps. Anton's voltage app also works great for amps and voltage and I use it too.
I do like that the way I have my DVM wired I can see voltage from a distance without having to walk over and key on and/or mess with Bluetooth. But your solution is without a doubt the cleanest solution for anyone that wants a clean or stock looking bike and doesn't want to mess with Bluetooth connections.
If I'm walking up to my bike while it's charging to check voltage and amps it's not really a big deal to key on so I think you probably made the right design call to keep it simple.
I like that that you are potting. I ride through all weather and the potting on the SCv2 control boards has performed flawlessly and I potted my DVM in the same way and it too continues to work perfectly after over 14k miles.
I can't wait to see and try out the finished product!
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