[RICK LAKE]

psychoSEAL The problem could be the contacts inside the relay. Over time they are burnt from the ampage being passed through them. The more they get burnt the high the resistants. Since you have had this system working for 2 years, I will GUESS that the wiring is OK and no chaffing in this curcuit. What is the amp rating on the switch? As said before the fan motor may have a dead spot and takes too long to start to turn. This will blow the fuse. The fan motor needs about 50-60 amps when turned on for the first 1/4 second. It's normal and it's a ampage spike.This is all it takes to cook a fuse. The fuses you have are probable slow blow ones. It just takes too long on startup before blowing one. Good luck Rick L. ps any chance you know a Watson? from the teams?