For the gelato: Scoop the softened gelato into a large mixing bowl. Using a rubber spatula, fold in the dulce de leche and malted powder to taste, if using. Transfer to an airtight container and refreeze for 2 hours.
For the chunnel cakes: Mix together 1/2 cup of the granulated sugar and the cinnamon in a small bowl. Set aside.
In a mixing bowl, whisk together the flour, baking powder, orange zest, salt and the remaining 1/4 cup sugar. In a separate bowl, whisk together the milk, olive oil and eggs. Make a well in the center of the flour mixture and pour in the wet ingredients, stirring to create a smooth, shiny batter. Transfer to a piping bag fitted with a medium-size star tip, or a re-sealable freezer bag with a corner snipped off and fitted with the same. Transfer the filled bag to the refrigerator to chill until very cold, 30 minutes to 1 hour.
Fill a wide, shallow pot or Dutch oven with 3 inches of vegetable oil, and heat the oil to 360 degrees F.
Working in batches, carefully pipe 3-inch coils of the batter into the hot oil. Fry until golden brown, 5 minutes. With a spider or slotted spoon, transfer the fried cakes to the bowl with the cinnamon sugar and coat with sugar on both sides.
For the sandwich build: Take one chunnel cake and place a scoop (about 1/3 cup) of the dulce de leche ice cream on top. Sandwich with another chunnel cake, and drizzle with some extra dulce de leche. Serve immediately or freeze for later.