Sounds like youre quite a way through the project. Im gonna have a try at a 2 channel controller because ive always wanted to do this since we started building robots, and now I have a team of people where I work who can help out with the development by providing me with support and ideas.

Im not sure how much the IBC controller costs.

What microprocessor are you using. Im thinking of using a PIC (PIC18F6520) as it has a good amount of flash and has separate RAM and EEPROM space so you can re-write the software on the fly (for upgrading etc)

Thanks for all the info

Dave