I like Han, but he's not without "flaw" to me... So I have to disagree on him being up there with Chewbacca. I'd put the new IG-88 and probably many other figures above him.
That's not to say he isn't great. I still love my ANH Han if I never got another, I'd be just as content with what I have. My beefs are lik ethis though:
-Non-removable vest... Minor perhaps, but I think it's acheivable these days without adding bulk, and it's a nice feature.
-Holster Thigh Strap Separate... This is more important to me, honestly. Bespin Luke, and many other figures, have since sported the thigh-strap as a sculpted part of their separately sculpted holsters, and I think any Han that has the thigh-strap sculpted to his leg and leaves the holster hanging is in need of upgrade (Endor Han, ANH Han, etc.).
That's honestly it, but it's an "it" that bothers me too, especially the holster. I think better Ford likenesses exist too, but they're few. That battlepack Endor Han, or the last Carbonite Han I like better. Even AT-ST disguise Han looked a little better too I think. SO I think there is room for improvement.
Still, this is probably my favorite Han Solo... He doesn't have the goofy chest of Endor Han, and he was pretty revolutionary at the time. Like I said, if we never got a new one, I'd be ok. But I'd not turn my nose up at a new one that fixed the above either, ya know?
Big Head Han? Ugh... I went to school with a guy that looked like Big Head Han. Creepy.