The whole unit was home made. Regulations are not a problem because there basically are none when it comes to what you're using at home. And yes, there is no no-volt release and no motor protection. I think it might be worth adding it.
I didn't check the current on all phases, would be easy enough to do. Did check the voltage on all three phases (only had a DMM with me) on the motor clamps and that was fine, but i guess that doesn't matter if there's a problem with one of the windings.
Is it possible that the breaker is so close to the limit when starting it needs a few seconds to "cool off" before its able to go through another over-amp jolt when switching to delta?