Run electric fans all the time?

Well... let's back up a bit ;) I started this flog because the temp will not drop below 194 on the highway, so the fans run all the time (both on high speed). That is indeed a factor of my temp switch.

But I can shut them off manually and the temp stays about the same.
To me that says either inadequate coolant flow or not enough radiator since there's plenty of air at 60 mph...

I don't have a problem with the idle temps, since I know that can be fixed with a better sensor and controller.

I only wanted to run mid 180's on the highway. Am I asking the impossible?

My opinion is your thinking is correct there. The fans will not be the issue. It's either not enough radiator or coolant flow as you mentioned. So that's either pump output, restriction, or just not enough cooling capacity from the radiator. Pick your poison to try first, its hard to know.