Alright, some updates on my PAM256:
3E Audio sent me a new module to replace my defective one. I wouldn't call it trivial to install these, but if you're good with a screwdriver and following directions, it's certainly well within the capabilities of your average enthusiast and doesn't take terribly long.
I am pretty impressed with the performance. I haven't done any measurements, but it was capable of driving the speakers to reference (and a little beyond) without any harshness (let alone clipping). I had been planning on getting a Buckeye 3 channel to drive the fronts, but now I'm not so sure that's necessary. I have a teensy bit of white noise coming off one of my pre-outs that I am trying to figure out - it's not there when I remove the RCA cable from the amp, and it was present on both amp channels I tried, so I suspect that it's the AVR, not the amp.
Auto-on works alright, but the 12v trigger mechanism is the way to go if you can do it.
The biggest dislike I have is that it simply isn't very good for rackmounts. It does fit, but you have to angle it behind the rails due to it being slightly oversized (by like mm's). This was a weird oversight by 3E Audio, so I hope they release a version that's set up for this use case. I'd like to see them release the modules for adding channels, too.