Mac Mini Overheating - probably my fault, still need help though.

Hi all,
Well first off my Mac Mini is out of warranty, so one day I decided to crack it open and take a look around.
I removed the heatsink and the dodgy heatsink clips apple uses (2 of which broke while removing them) and was forced to buy some plastic screws to hold the heatsink on.
Ever since doing this my mini has been experiencing problems with heat.
Its a 1.66GHz Intel Core Duo (1 GB 667 MHz DDR2 SDRAM) 80GB Hard Drive.
It already has the latest SMC firmware.
I have tried the SMC reset procedure, while the procedure did work the problems persist.
First question, what should be the idle temperature of this machine? it is idling at 60* Celsius or 140* Fahrenheit and 1500 RPM fan speed, the problem is even at 70 - 80*C or 167* Fahrenheit (full load) the fan only increases to 2300 RPM which is insufficient to cool the machine, resulting in a kernel panic and possibly triggering the Intel CPU's thermal protection circuit.
I have checked the CPU numerous times and tried various thermal paste quantities but this problem persists. I have also checked the fan connector which is definitely connected correctly, in fact all connectors are connected correctly I am sure of it and the reason I am sure is all the software is reporting the correct numbers for temps voltages currents etc.
Does anyone have any idea what i've done wrong apart from ever looking inside this thing in the first place? I really want to save it because it works fine apart from this issue.
PS. The only way to do any work is to do an SMC reset (during which the fan runs at full speed), while the fan is forced in full speed the thing works great but as soon as its back to normal the fan fails to adjust adequately).

It sounds like your method of attaching the heatsink is not as good at removing heat from the CPU as Apple's was.
I'd suggest getting one of the fan control programs and setting the minimum fan speed at 2500 RPM or more.
Another issue is whether or not you correctly replaced the T-shaped foam air-diverter on top of the hard drive.
Also be sure the Mini has free access to room temperature air, and is not sitting on or near other heat-producing equipment.

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