Just a few thoughts and observations from a non-expert who didn't sleep in a Holiday Inn last night.
-The fan idea is a good one, especially for where you will need it- offroad at slow speeds.
-The tube/fin versus plate/fin argument may be null, if each cooler's GVWR recommendation is followed I don't think any one style is going to be superior...smaller or more efficient for a given size, sure, but not better.
-Going to a 160° thermostat is interesting, but once you hit whatever temp the thermostat opens at then any temps above that point will be controlled by the cooler and how hard you are pushing the transmission.
-Bypassing the thermostat to check restriction is a good idea.
-I think that while 180-200 is a good range to be in (and below 160 the torque converter will not lock up to generate heat? ), don't get hung up watching the gauges and get tunnel-vision on what may be a non-issue. The charts list maximum temps and lifetimes for temp ranges, but I believe that high transient temperatures are okay if they only last a short while (until you get above about 235 tho, the closer you get to fluid breakdown the shorter amount of time you should spike up to there).
-An auto transmission makes heat the harder you push it, either by slipping or increasing pressure to hold against slipping. If your transmission is old, you are going to see slightly higher temps than a new transmission. You may have to go to a Corvette servo to increase holding power. You may need a new kevlar band for better holding power and a shift kit. Your bands may be slipping slightly, you may have worn friction plates or warped steels that are still functional but then you will have to tear into the transmission to fix an internal problem causing higher temperatures. Is it worth the time and money to replace/rebuild your transmission now or keep driving it for another 30-50k miles until it needs a rebuild.
I don't know what is causing the high temperature issues and agree that keeping the temps in that 180-200° sweet spot is good but don't loose focus and forget that your transmission IS operating properly. Good luck with getting it sorted out, from my own engine temperature and transmission issues I know it can be frustrating.