Quoted from SJ23:So do you think I've narrowed it to flipper switch returns or the mains? I feel comfortable checking/repairing flippers but not mains. I'll give it a go and see. I'm like 15 fuses in now
Are you talking about the flipper switches inside the cabinet?
no I don't, but that is all that is left on J2 and doesn't explain the GI fuse going open.
and now you mentioned the problem existed prior to the new rec board I'm guessing to a short in the cabinet.
yes to flipper returns inside the cabinet, the actual flipper switches themselves, and yes to only connector for the door.
with the power off check the wires in the cabinet, you may need to cut a few cable ties? I'd be concentrating on following the GI wire, pin 1 on J2 from the female cabinet side back to J2. F1 is for your GI and that's the only wire (for the coin entry lamps).
Actually with J2 and the connector unplugged, use your meter (assuming you have one) and check for continuity from the J2 pin 1 plug (the probe tip should fit in from the wire side) to the other pins in the connector, you shouldn't hear a beep and/or see infinite resistance. But in your case you do want to hear a beep. If your meter beeps then you know which wires to look at. I'd assume you will get a beep and this will be the cause of F1 going open, if not I'll join you banging your head against the brick wall.
it sounds like the GI is shorting to ground.
it's unlikely but there could be solder blob that has shorted 2 wires, I say unlikely because it would have to some heavy duty blob to melt through the insulation and join 2 or more wires.
it only takes the thinnest of stray wire strands, just one to cause a head f*ck.
it might be a bit late, but ideally you'd have purchased a circuit breaker and soldered a blown fuse to it, found on ebay, https://www.ebay.com.au/itm/403405655263 that you simply press a button resetting the fuse instead of going through fuses.
If the above fails i'd remove the wires/pins from the connector except the mains wires 6 & 7 (yellow & blue) and connect the plug and see what happens. If the fuse blows then it's the board or even though you've checked and checked the wire connections to board, it still may be them or the board is shorting on the ground plane. You can remove the rectifier board from its stand offs (to eliminate a short to ground) ensuring it's sitting nicely away from anything and power it up. If you are 100% sure the board is in no way touching the ground plane then don't bother. But the aftermarket rec boards I've seen have a connection from the rec board ground to the ground plane, so if your board has this you can remove it temporarily, just for the test.