If you're going to have someone take a look at it for you, make sure you provide them with access to the Wii Trimming Guide and the 4layertech page for the PMS so they can reference the wiring diagrams
Moved to The Cutting Edge from the 2023 Contest section as you don't have the Contest role and this project lacks sufficient photos with the proof card.
Great project tho. I really like the way you built the case so neatly from scrap plastic. Good frankencasing is becoming quite a lost art
Disconnect the PMS-Lite from the Wii and check the output voltages while it's on its own. If they're still not correct, the PMS might be damaged.
When you are able to, please provide some clear high resolution photos of your PMS and Wii wiring so we can properly see the current state of it
Fortunately the heatsink & fan combo Nintendo used in the Wii lineup is pretty overkill. Any build that uses both and has enough intake holes is pretty damn thermally safe. If anything, the Noldendo Wii Micro may have better thermals due to having a way larger intake grille and an almost...
According to the datasheet for the regs used in the PSU-Plus, 12v input is safe to use thanks to the regs having an inbuilt thermal safety. If the regulators get too hot, they will slowly ramp the output current down, shutting off completely if the sensor hits 160 degrees celsius. Getting that...
The greater the difference between input voltage and output voltage, the hotter a regulator gets. Usually a difference of up to 10v is fine, but the 1v reg is slightly outside that range and could in theory wear out faster than the other regulators and fail. It's unlikely, but it has happened...