PROMISE: I'M NOT COMPLAINING
Okay, so, whether you're tired of my posts here yet or not, here goes another one:
goodvibes: You were right. Surprise, surprise.
A while back you mentioned the button stiffness that I had commented about. When I first opened this unit I removed some of the adhesive-lined padding on some of the components. I then sort of ripped apart the padding that was on top of the Micro SD card reader (it was under this that I first found that renegade screw). I THEN placed the foam back down...imperfectly - meaning I didn't line up the jagged edges of the tears exactly. This raised the padding by about about .25mm - .5mm. This caused the button stiffness. I loosened the board (as you suggested), but of course with the padding being slightly thicker, it just pressed the board down against the case anyhow.
THIS seems to have been the cause of the short. I noticed that when giving the unit a squeeze from front to back the menu would self-navigate as it were, meaning either the left or right button was being pressed too. With the constant pressure of being attached to my portable amp via some thick rubber bands, it may have been pressing a component against the aluminum casing - perhaps a component that only had current going through it when plugged into the usb (hence the rebooting while charging?)
Whatever it was, removing this unevenness int the padding helped immensely.
Everything is working fine again.
I swear I'm going to stop causing problems and then explaining how I solved them
Who knows, some of this info might be useful to others out there - one can only hope!
Thanks to you all!