[JohnnyOhh]

how much current do you run through your set-up? sounds like you would be melting if you are generating a lot of heat, the only time you would generate a lot of heat is if you have high current + high resistance together. and the heat will generate where the high resistance is.

The plastic that the fuse holders mount to will melt eventually and the 2 power wires will end up touching and popping fuses.

what do you mean by this? if power wires touch each other it shouldn't matter, do you mean the power wires touch a ground point or touch some ground wires.....?

Resistance/crappy fuses (don't blow when they are rated to) are the only things I can think of that would melt a fuse holder not on the exhaust manifold!

This above sounds likely, can you try brand new fuses next time? Also, just try no ferrules as a test.

Also, also, pics will speak a thousand words in this situation.

 

[JohnnyOhh]

in terms of troubleshooting, i think the ferrules add extra complexity.... so that could theoretically add extra issues/parts failing.
i actually used them first tine in my last set-up, they worked well for me. i personally don't dislike them or anything.

do you have any pics of the burnt/damaged fuse block? your stuff looks nice..... man this is a brain scratcher. what about pics of the fuse block where it is actually mounted?

 

[JohnnyOhh]

if you tug pretty hard on the black/brown wires.... they don't pull out, right?
could the set-screws be backing out a little and getting loose over the course of 1-yr or whatever? causing intermittent connection?