Just come onto this thread and we need to go back to basics.

Transformer in question is the 6.3VAC and 25VAC output yes?

Firstly, make sure the transformer is wired correctly and that the -ve AC side is taken to COMMON and not ground. Reason for this is that often common can be sitting at 20VAC... your solenoid AC output at 60VAC ( when referenced to ground)... the machine only see the potential difference of the Common and Solenoid AC output... which would be 60v Minus 20V =40V.
Reference to true ground and youll get higher readings... you are only interested in both outputs of the AC windings.

I  don't understand this statement:

it’s smashing the ball around with GI the running, perfect without GI fuses

Are you saying that the GI is running Ok without a fuse installed??..If so - you have a bypass of the fuse somewhere.
Am I reading you right when I say that GI is running without a fuse installed and when you do install a fuse then the coil voltage rises but lamps do not blow?