...Probably, this mixture of cables have conduct to a higher abnormal intensity
Doesn`t the current intensity depend on the electric consumer? In my case The BT-module is not connected in series to an other (bigger) consumer. Furthermore I measured the complete consumption of current which is similar to measured value of my other (also BT modified) Merlin: with BT 98-100mA, without BT 36,3mA. The difference is 63,7mA. Don`t know if this is normal for You`r module?
I don't really understand why you have removed the connectors from the PCB and why you have make direct soldering on the PCB
The connectors otherwise had to be insulated and clip off on the bottom side of the PCB, because I glued it with double faced adhesive tape on a plastics part, which is applied to the cover of my metal housing.
Those connectors contribute to the global cooling
hard to believe that cooling would be noticeable better with this connectors/pins.
you have placed the Bt module into a "closed" metalic box ... this isn't perfect for cooling !?!
My metallic box isn`t really closed. I milled a notch into the cover and placed a plastics part in it alone because of the radio transmission. As You can see on the photos, the plastics part is also milled and BT-module is placed in the milling groove, with antenna surface externally to the outside. BT module is glued on thin plastics part with double faced adhesive tape, in also the same manner as You do it in the original blue plastics box.
metalic box...isn't perfect for cooling
This is an interesting issue. I know nothing about the blue plastics material, perhaps it is optimized for cooling but I know that aluminium is a good heat cunductor, often used as material for cooling parts.
Clearly the PCB (printed circuit board) has been "nearly burned" at some places
I`m not proud on that but that`s my fault
I don't see the small wire "antena" anymore, this can cause limitations in operational distance ...
It`s in original condition. You can`t see it because it`s on the bottom side, which is glued on the plastic part
...but in domain of electronic .....
You`r right, I agree
Thank god I don`t have to make money with electronic