Run electric fans all the time?

DrCharles said
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?

We're bouncing around here.

You've identified three issues so far-

Underdrive pulley on the water pump
Standard water pump mismatched to pulley ratio
temp switch instead of a controller

I would fix those issues before doing anything else. You should either drive the water pump 1:1 with a high flow (8 blade) water pump or 1.4:1 with a standard 6 blade water pump. Matching your pump and pulley ratio alone has the potential to make a huge difference. Then get a better fan controller, if you even still need it.