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I'm still a bit confused about the setup so apologies if this doesn't make sense, but could you have accidentally changed the voltage ratio on the ECU (if it's aftermarket/standalone) so the gauge is reading the incoming voltage indirectly?
Could be the fan is just on its way out so it seems like there's a wiring/gauge/sender issue but actually the fan is just semi borked?
Given they're cheap, I'd get a new thermostat first and a new sender for the gauge and see what happens. Are you using an MX5 rad? They make alu versions that I've got that are much better.