Another thing to try with the gear is to eliminate the controller and see if that helps. You'll cook, of course...but at least it may rule that out (or in), especially since it's popping so quickly. I went through a couple of those plastic ones...picked up a Heat Troller when I got my WnS jacket so I could prevent future issues - and the stupid thing has been fine ever since! Go figure.
"Triumph over adversity is good for the soul." -- Packmule
IBA# - 18804