MOSFET getting hot and making noise

[(*steve*)]

Would you still recommend this in lieu of my above comment? Is there anything else I should check to confirm it is functioning properly other than input current, output voltage, and heat? Thanks!

In light of it now functioning, no.

The voltage regulation really only works by accident. If it's working, don't mess with it.

I suspect that with a better design the quiescent current would be closer to 20mA than the 40mA it is now, but that's not a huge difference.

I suspect that what you've done by wiring the grounds to a large area of copper is to create a star ground (which is a good thing).