After trying with another relay when problem still persisted, the mechanic tried to trace the wiring in engine Bay. Now the fuse was blowing immediately instead of after some use. He connected the condenser directory, and it was working fine.
So the only way left was to open the dashboard
And Voila the short was there. Near the stereo there is an iron bracket to hold the AC blower and stuff. It has a sharp edge. The AC wire was cut there, and while driving during jerks and stuff it would touch the edge, and hence the fuse would blow.
Many other wires were also on the verge of getting cut. So he fixed cable ties etc., properly put electrical tape multiple layers around the wires, and re-arranged the wires also.
I had also complained about air flow and less than adequate cooling(not as much as a new car) even after gas recharge.
When he opened up the blower area, all the cooling coils were covered in dirt and grime(6 years of usage does wonders).
He went to an AC guy and they said they can clean it only after removing the assembly, so gas loss would be there and recharging is 800rs minimum.
So in a fix he decided to do the job himself.
Bought a chemical bottle(cleaning chemical used by shops) for 260rs, and found an old fuel pump lying in his box.
Filled up a clean tray with water and put it under the assembly.
Connected fuel pump to battery and put its suction filter inside the tray, and started washing the cooling coil system vent by vent.
After an entire bottle of chemical solvent, few bottles of surf in water and then a few bottles of clean water, the cooling coil assembly(from which the blower draws air) was clean!
The he refitted the blower etc.,
The Blower assembly
View of the dash. Finish levels are apalling but surprise surprise, the car has a rat grill factory fitted. The mechanic told me that most cars do not have this and rats can get in the cars in areas where infestation is there.
After the entire cleaning process and fitting the blower the dashborad refitting started.
To put things in perspective, the work started around 11:30am, and the blower was fitted back around 5:30pm(1 hour for drying coils).
By 9:30 the dashboard was put in place.
Total 10 hours time with 7-8 hours of hard labor.
Charge including the chemical bottle came to 1250rs(rolls of tape, elfy etc., included).
The Results were amazing. AC was feeling cold. Real new showroom car cold. I never expected a cleaning to yield such drastic results!
Since yesterday no Fuse trips, and everything is working fine! There is slight smell because carpet got a little wet, so she's parked in sun with windows slightly open.
But the slight foul smell from AC is gone completely.
I guess once in 5 years a dashboard opening and coil cleaning job is a must considering the dusty environments we live in!