..Thanks for all the suggestions guys....I will see if I can make it over there to look at it tommorrow...Will post my findings..I think I may start with a battery swap...can't remember if I had checked for voltage to the frame (of all the things ive lost, I miss my mind the most!)

if it "only does it when plugging", you might want to check the plugging diode. I would suggest checking it with a handyman rather than just a VOM.
I would also be checking real close as to 'shorts to frame, in particular the heat-sink the plugging diode is mounted to.
and of course, ?got good battery?,,, ?under load???

Well... since you've replaced all the suggested problem components stated in the troubleshooting guide for this panel and your problem still exists it sounds like it's time to start looking for other causes that are in those circuits.

check for wiring issues, bad crimps on connectors, pinched wires, loose connections. Check the ones on the capacitor wires and make sure all the connections are tight. I have ran across assorted strange problems with these panels like the center screw in the spider block where the capacitor wire connects to the choke circuit, the screw was not tapped completely and would not tighten up all the way, had to go in and tap out the hole more to get the screw to seat properly.
Had another one where the wires on the capacitor looked normal but after closer investigation i found one of the wires even though crimped well they had not scraped off the coating of the solid wire well enough causing a bad connection.

Sounds like your in for some fun times on this one :o)

good luck