If the fuses are properly sized and are of the ANL, Class T or MRBF type you really should not be having those problems, and yes, it could get very expensive. I would guess they were sized too close to the load. Breakers can be fine so long as the AIC is sufficient enough for your battery bank. On larger banks the AIC of breakers is often not enough. I've installed hundreds of bank fuses, three this week alone, and not one nuisance blow. Often times the wire is the limiting factor in matching a fuse to a starter but the ABYC allows the fuse to be up to 150% of the Table VI ampacity ratings. When I get a moment I will post the ampacity ratings.