Cajun Injector XL PID Build

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looks to me like you exceeded the temperature rating of the wire insulation on that one piece of zip cord looping across your relay  Then either the zip cord leads shorted together or one of them touched the conducting output screw of your relay causing major short.  

Next time, use a box listed for AC line use, add a fan, and route/dress your wires so this can't happen again.  

Like you said, your relay gets hot and you had no way to get the heat OUT of the box.  
 
I forgot to mention i did rig up a fan so heat wasnt an issue then again i could be wrong.
 
can you show us (photos or diagram) where the fan's intake and exhaust were?  Hopefully the relay is in the direct air path?  
 
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