OK

Everything ponts to a bad fan motor/wire connection

Are you sure that the fan you used for test is good .. this is very important cuz if you are not positve about that, it throws off the diagnosis..
I would separate the fan and try each alone .. If you have an amp meter , I would also get some draw readings
Lastly, you could also have a high draw caused by bad wire connections .. the most suspect on these will be at the fuse terminals, at the base of the relays [ there are two, located in slots B and C behind fuse box], at the dropping resistor. and the ground side of the fans..