(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.
There are also additional upsides. In addition to making the Electoral College more closely match the popular vote (I should say again, because they used to be much more closely aligned than they are today), smaller Congressional districts are harder to gerrymander to very much effect.