Could be a bad contact on the NC side, although I would expect that to fail when you pop it open to coast (ie you wouldn't be able to bump start it after a glide).
Two things would be my first guess. If the wire that runs from the relay to your switch rubs anywhere metal, it might rub through the sheath and ground out. This would be intermittent and hard to catch, depending on how it happened. The other possibility is the switch got stuck - with that long neck, if the switch isn't centered it will activate the button, even if it's not depressed. I had to over-drill the hole by quite a bit (maybe a full mm larger than the button all the way around, or 2mm diameter) to make sure this wouldn't happen. I had the same issue when I built a case for my MPGuino.
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