The BBSHD does not have FET issues with the controller. The BBS02 needs the higher revs, and good sifting technique. Used as designed, there are good to excellent results. It appears the BBSHD has more power, better cooling, and there are less limits on the bigger drive.
I'll likely replace BBS01 with the same model. It's my favorite bike path motor. On a flat foot frame it's just comfort.
I only ride commuter style. Most rides are errands are 1-5 miles. I run the HD 42t x 22. Fast enough for me, an easy 24. More speed is available, but 25mph is max for my bicycle brakes.
Fit is important when deciding on the chainwheel, as well as chainline. One size does not fit all.