(However, I do think we should expand the size of Congress which would greatly mitigate the problem of a disparity between the Electoral and Popular vote.)
I’m not so are about the Congress idea. 535 people is already quite a a lot to know, and increasing the size of Congress might introduce new inefficiencies and make it harder for Congesspeople to collaborate. I hear this is a problem in the EU legislature.
There are downsides. As you politely observe we have quite a lot of uncooperative nitwits already. The Capitol would end up looking like the Republic Senate too. But there could be some way to work out the logistics. I don’t know how the Chinese National People’s Congress works but I guess it does.