30amp fuse Blowing often

Chances are the windows and head lights just need new brass gears along with checking and the connections? As far as the 30amp fuse/breaker I can't help you there, but in short time someone on this forum will be able to help you out!
Let us know how things work out.
Good Luck

Are the 30 amp fuses a glass tube fuse?
If so....I had a similiar problem and found that the fuse didnt actually blow but rather the soder in the end of the fuse melted and ran out of the fuse causing a circuit interruption. I temporarily replaced the glass fuse with a blade fuse and solved the problem. Over the winter I replaced the fuse block with blade fuses and we will see how the summer season goes.

You might have had a high resistance connection with the fuse especially with this style fuse. As for the updated fuse box, it really depends on which one you opt for. Some take the stock fuse block and replace the old bullet fuse assembly with blade type assemblies. Nice because its a plug and play and, since it uses the old fuse block, goes right back in. There are also updated assemblies available which have the relays installed which would solve this and other issues (overloading the ignition switch, window switches, etc). I would try replacing the plastic gears with the brass ones in the window mechanisms. The biggest advantage of the Aerostar motors is the speed. The windows will move faster with these motors. The PanteraPlace website has an excellent write up on this conversion. You need to be careful as to which motor you get since they come in 3 bolt and 4 bolt varieties. The microswitch for the headlights is on the drivers side near the top of the radiator. It may need cleaning or adjustment or both. Replacements are available. Be patient with the electrical problems. There are a few weak points but once fixed they shouldn't be an issue again.

The Ford Taurus motor swap is easier than the Aerostar conversion, just not as easily reversed. But then again why would you want to ever go back!

I did the Taurus conversion last week. Time consuming but very easy and cheap. Both used motors cost $19.00 incl shipping. See SOBill's step by step procedure. One additional thing you need to do, if the spring is rusty, clean out with brake cleaner & pack the layers of the springs with axel grease, takes about 4 minutes & about a teaspoon of grease.

Tip: Use a Dremel & cutting wheel to cut out the regulater for the Taurus motor. You also use the Dremel to cut off the three mounting studs on the regulator from the old motor. This was the first time I did anything like this. I went slow and it took me about 4 hrs/door not counting watching SPEED. I could do it again in about half of the time, but isn't every project that way.

Instructions:
http://www.panteraplace.com/page164.htm
This is for the Aerostar conversion but excellent pictures & instructions to remove the window regulator, use step "A" only. Then go to the Taurus conversion from SOBill Taylor. I printed the instructions and pictures from both.

Here is the link for SOBill's instructions for the Taurus motor conversion:
http://www.panteraplace.com/Page187.htm

After doing the conversion, I don't understand why anyone would want the old motors in the car & replace the gears. My nylon gears were not broken & the windows were very slow. You do 3/4 of the conversion if you just replaced the gears. The Taurus motor has much more torque and uses 1/2 of the amps as the old motors used. The windows move up and down at a modern speed.