[psychoSEAL]

Over the past few weeks I posted a problem with my fan relay. The wiring has been in place for almost 2 years and no problems. I uncovered a blown inline fuse (no big deal) replaced and the fan started working again. Until the next time I drove the car and smelled something like an electrical burning smell. Thus, finding the inline fuse holder melted. The relay wiring is from SPAL with a 30 amp fuse and a 40 amp relay. I also had it wired to where I could manually turn the fan on if ever needed. The fan is from a 89-95 3.8L Ford Taurus that I wired to the high speed fan and not utilizing the low speed. After reading a number of post on this site and a few other sites, I uncovered the fact that a Taurus 3.8L fan puts out around 4500cfm and requiring a higher amperage relay. Now, after 2 years do you think this is the problem with my blown/burnt fuse and fuse holder? Should I switch the setup to where I am not using the high speed fan and go with the low speed? Do I go with a higher amp relay? I like keeping things simple with the wiring because I am not an electrical magician by no means. Ideas? Thanks!!