What a great looking build. Nicely done. What is the ambient temperature of your brewing space, and how often does your AC unit cycle on to maintain the 68 F in the top chamber?
The Corning I have is Model PC-320. It is rated at 575 Watts. It does take a while to bring a larger wort volume to a boil, but I have never found it to be a problem. This one is a bit pricey, but it is the model I own...
I use a Corning combo stiplate/hotplate, and I have found it works great for making starters. I typically make larger starters too - some even as large as 4000 mL. I typically bring my dechlorinated water to a boil in a pot on the stove, add the DME to my 5000-mL flask and add the boiling...
I use a Minibrew HLT and have the same problem. Unfortunately, the only fix I found was to indeed put a gang box around the element connection. I've noticed that the problem has subsided some as of late, but that is probably because the lid has deformed in shape, and the condensed water...