Have you checked / cleaned the metal contacts where the blade fuse actually pushes into, for a fuse to slightly melt I would say its getting a bad / dirty connection as poor connections create high resistance which leads to excessive heat to the fuse or whatever connector is loose / dirty .. Technically a fuse should blow before it starts to melt unless the heat source is a poor connection near the connector .. If the connectors are all good, which headlight switch do you have in now ? I would be putting the spare one back in .. Also the big 30 or 60 amp fuses wont be the fault as you would have a lot of other things dead in the car too if one of the Big fuses had died ..