Newsbump, finally got there. Fuse is lower than given rating, and the plastic end of plug has melted around the tip of the jack. Kinda lousy cam pic, but should give a good idea..
Gonna get it to service, but any ideas on what might have gone down? Could there have been a continuous bad connection between tip and Jack that has caused the tip to heat?
I don't think it was mentioned but I think you're right. Could have been a poorly fitting 1/4" plug (or a really worn 1/4" jack) and the vibrations could cause inconsistent contact and cause it to heat up.
With your rehearsal supposedly "loud" I imagine the noise made by this could have easily been covered up by overdriven guitars (or if you use a lot of overdrive) and your ears losing sensitivity. It might have even happened fast enough that the jack melted and actually caused it to make better contact and then cooled down locking the plug in over the course of one song.