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No wonder you're making more HV, you're putting in too much power at the AC side. Turn down the power to 117 VAC, then tell me how much HV you end up making... You'll be struggling just like the rest of us. That also explains why your fly is getting warm, I can run mine for hours on end and it's not even thinking of heating up.
This is why I'm in favor of modifying the chassis for more HV, instead of simply cranking up the power at the plug. There has got to be a way to make these things better, without risking the horizontal output transformer.
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Evolution...
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