I've been real hard at work over the past few days. I've got all 5 beta units assembled and they are working well. I've figured out both dial issues I was working on. There is some free space inside of the power brick I am using, so I've mounted the dial within it. As well, the dial now is much less sensitive, with an upper limit of around 14.5 volts. The voltage fluctuations I thought was based off of the wall power is actually the dial, so they have also gone down. There are still small fluctuations, but they are only apparent when the VVPS is turned on cold, and everything smooths out once things warm up.
Here's a slightly crappy phone picture of them all laid out, ready for packing. I'm nearly completely happy with the units now, having only made one compromise with these beta units - that is leaving the circuit exposed. I still haven't found a solution I like in terms of wraps or containers. I will be investigating more options, but for the sake of expedience I think I should get the working units out to beta testers soon.
There really are no technical downsides to them the way they are now. The circuit board is exposed, but it's laminated to protect it from atmospheric moisture and other problems.
And here is a more in depth look at the beta unit:
I'd also like to thank Sticksstones, Alan, AdmiralAlchapa, Ed and MVapes for volunteering to be guinea pigs on this project. Dreamerr deserves an honorable mention as she was going to be doing Arizer testing, but unfortunately I have decided to drop Arizer Solo support on these devices for now for several reasons. The solo is very sensitive to changes in voltage and until I find a knob that can lock into place it's too dangerous for the solo to be connected to these.
I plan on having a beta testing period of at least two weeks, so after that is over with I will have a better idea of when these will be available for general purchase. Thanks again everyone, I'm really happy this project has moved forward as it has.