If the insulation melts and two wires touch each other, that bypasses the ignition switch and would be the cause of the problem. Unplugging the switch wouldn't help but you should be able to see any wires melted together.
I'm still going on the assumption the starter cranks intermittently. Is that right or does it crank all the time unless you remove the starter relay? Have you tested for voltage on terminal 86? If you find anything there, wiggle the fuse box and wiring harnesses to see if anything makes that voltage change. Terminal 30, I think, has 12 volts all the time. If someone had the fuse box apart previously, it might be possible for wires to get mispositioned or stretched until they touch. Applying 12 volts from 30 to 86 would be the equivalent of turning the ignition switch to "crank". If this problem acts up intermittently due to wires just barely touching, wiggling things should help to identify where to look closer.
Sunday, February 5th, 2012 AT 11:48 PM