mrfixit you are fairly close to him compared to the rest of us, maybe a roadtrip is in the making?

Alot of good suggestions have been made here about this problem and from the sounds of the replies space brings back to us and results he is definatly in need of some professional help.
Its been many years since i've even seen an EV1 panel in a truck but from what i can remember generally they are easy to diagnose and fix but this one sounds like its in need of someone more experienced.
yes alot of time and 'some' money has been used up to try and diagnose this problem. Maybe its time to get someone experienced in this system involved. ;o)