Are you melting wires, or melting fuses? Since you have the means to test amperage, why not run the engine with no electrical load, and see if the huge load is caused by a specific system, then narrow it down?
Is the battery in the engine bay, or did you relocate to the trunk? 4 AWG cable is good for runs up to 10 feet, up to 100 Amp. Any longer, or any more amperage, and you need to use 2 AWG.
If your engine grounds are crappy (the large ones on the passenger side near the battery box, and also to the block in that area) you will see a larger current draw as well.
But hey, great job on having AC! We have the same setup as you, and the wiring for that is kicking our asses right now. lol. Good luck.
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