A couple more ideas. First of all, what do we know... the DMD cracked, fuses blew (solenoid, lamp, 5V digital), both insert and flasher LEDs melted (and it's not the first time LEDs have melted in this game). Thinking about what these things have in common, maybe it's time to look upstream towards the power transformer. Could it be failing, with a winding in there that shorts out intermittently (creating overvoltages)? I haven't seen that before, but does the transformer smell like it got hot? Any evidence that a liquid spilled into the cabinet? I wonder if you can re-create the problem by jarring the transformer and/or harnesses while the power is on.