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I'm curious about the conditioning part. The 7805 should handle that, it's rated for up to 33v (I think), it should be doing that part.
Since you are working with your prototype, is it possible something shorted out some pins? (That's why I wanted mine in an enclosure before I take it on the road)
Did you possibly over-rev and send a surge? I used to have an old Subaru that would blow a fuse if you over reved.
What about the board? Any discoloration or scorching? Anything look melted?
That's why I asked if anyone was fusing their power input and if so, at what amperage? Any concern from shorting out the Guino adversely affecting the automobile?
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