Only the fans are hooked up to that fuse terminal.
So if a 25A fuse can't carry enough current to get the relay to work, and a 30A fuse will - but heat up enough to melt the plastic, that tells me the wiring for the circuit is marginal at best. But if I increase the wiring capacity (12 ga. instead of 16 ga.) That would blow the fuse everytime the fans kicked in, no? Sorry, my brain cells just aren't ampere-friendly.
