Noting the time of your last post, don't want to give the impression that all I do is sit around waiting for you to post.
Just sometimes hit it right (LOL).
it is a common problem until you put heatsink on back of them
(from your post #102)
Have you done that? A
very good idea from the onset, given the current draw for "normal" stuff. Course, have no idea what sort of extra design/work that might entail.
For the extras, (6.5A), the 12VDC items really only need fuses.
The USB (5VDC) items are, as you have seen, a bit more problematic, due to they're sort of "finicky" ( an electronic technical term...) power requirements.
That part needs to be carefully addressed. Perhaps by scavenging your existing mini-power supplies (that we reversed engineered) and mounting them in their own box/
just a thought.
One thing to remember is that a single chip regulator's attachment point is electrically "hot", so the heat sink needs to be situated such that it cannot short to ground.
Have you guessed I'm enjoying this yet.lol
Yeah, did get that impression...