Hodgkinson wrote:
...slapped a 5V1 zener & resistor inside the PSU to regulate the rail...
Hi,
Are you sure you're using a zener correctly? I know you have some expertise with electronics, but from what you've written, I wonder if you may be trying to use a zener to provide regulation of an output rail. That is unlikely to work for the output power of your supply. I haven't used descrete zeners for some time, but I think they would generally only be used to provide a reference voltage for a negative feedback output level monitor. The error signal would then be used to regulate the output power transistors.
Sorry if I've misunderstood, but thought it worth mentioning.
Cheers,
Oli