Regarding the 30 amp fuse mod, I think there's some merit to beefing up the 30 amp fuse itself with a larger more robust 30 amp maxi fuse like the one in the link below. I've trolled thru all the electrical threads and I don't recall anyone mentioning this as contributing to the solution. When I described our problem to some electrical engineers where I work, they were in agreement about beefing up the wires/connectors but also suggested going to the 30 amp maxi fuse rather than the wimpy standard 30 amp.
You can find them at most auto parts stores, but would need a larger fuse holder.
Thoughts?
http://www.doityourself.com/invt/u156810