I'll have a look at the KV rating next time I'm servicing one. Unfortunately the ESC's are integrated into the ECU's on all our forktrucks, pallet trucks, etc.

I'm thinking of getting around the bar spinner problem by building a whole body flipper with a bit of flexibility in the hinge and ram, so that if it gets a hard whack and goes slightly out of line it won't stop it working. Is this a stupid idea?

Like I said in my initial post, I can't start building anything until I get my 240 on the road. I think a 400bhp/400ftlb Estate would be the ideal transport for a heavyweight.