Just spent 4 day weekend in ocean city md car show. 1000's of hot rods and pretty good weather. Police were not too bad this year. They seemed a little more lenient. Everything was fine until i noticed the temp going up. Pulled over and found that both the 30 amp fuse holders (bcool fans and wiring) had melted pretty bad. It looked as though this has been going on for some time. Finally got the fuses out and replaced them and it seemed to work fine. YEsterday, i went over all the wiring and everything seemed ok except i was able to turn the relay nut about 3/4 turn. Fans are wired to the starter relay. Is it possible the nut was not clamping good enough?

Sorry i am not much help but you picked a good weekend to test your cooling system. I was down there friday and saturday and i dont think i have ever sat in that much traffic in ocean city in my life. Hope you get your problem fixed.