I have a Salsa Fargo converted to an E-Bike and running a very old (+8 years) and now noisy BBSHD with a newer 52v battery. The set up weighs about 55 lbs and is relatively easy to put on a rack for exploration rides. The problem is either it is getting tired or I am getting old (78). Grinding up steep fire roads are a little more difficult each year. I am considering replacing the BBSHD and battery with something that has a little more power. I understand there is/are options to go to 72volt set ups but not sure what to buy or where. Looking for some advice/guidance.
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I am a handful of years younger than you but I feel your pain. A few things come to mind. It could be as simple as setting your max current higher. Second, based on reading I have done 60v is a good compromise for battery voltage. I believe it does not require an updated motor controller. Third, research "shunt mod" for BBSHD. This increases motor current fairly reliably and there is a supplier on eBay that is recommended. Sorry I don't have more particulars for either of these things. Lastly, HIgh Voltage Light Electric Vehicles has some powerful and expensive solutions for BBSHD. Good luck.