To complete the story in case someone picks up this thread, the noise has completely gone after re-greasing the gears, which was a fairly simple task. It's now quieter than say a Bafang SWX. I soldered the shunt in the controller about 25% of its length, which now gives 20 amps.
I've done about 200 miles with it over some very steep hills. I think it's brilliant. I'll now convert a better quality bike to use as my main bike with this motor.
I tried it with 44v at 15 amps, which made it a lot faster, whilst still keeping its climbing ability.
The only hassle with this motor is its width. You need to stretch your frame a bit to get it in. You need about 155mm for a disc brake. I did that fairly easily on my cheapo steel-framed bike, but my aluminium Rocky Mountain took a bit more persuasion. I had to stretch it to 220mm before it took on a permanent set at 150mm.