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RE: AC neutral return caused main fuse to jump

A ground-fault interruptor will open the line if the same amount of current passing down the hot phase does not appear on the neutral.
So, that's probably what's happening. Somewhere, something is using
the earth ground as neutral in your chassis - so the GFI sees a current imbalance and promptly disconnects both phases to the load. The GF breaker is sensitive down to the single digit milliamp range too, so you might not even be able to "see sparks" by shorting neutral to ground.

So where is you neutral to ground phase leak? Just because a DVM shows
infinite ohms between neutral and earth doesnt mean you're out of the woods. :) A capacitor will gladly shuttle 60Hz AC while "blocking" a DC path. It's probably capacitatively coupled...

-- Jim

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