Quote "Electical hum with the bonnet open there was a kind of noise behind it like an electrical spark jumping from 1 circuit to another. "
Its been quite a tale of woe, it seems anything done to cure the original fault has made things worse, ie fuel pump, the overheating/cracked C/Head.
I assume that the BSI reset was done at the time of the first b/down.
Could it be with all the dismantling and rebuilding that an earth wire has been missed somewhere or not tightened properly?
