Okay, so the cutting in and out problem did indeed come back some weeks after my earlier post. I am going to revise what I said in my original post: I do believe that this is a design flaw in the Helix. Further, I believe that the guitar conditioning circuit is shorting out against the metal case.
If you look at the attached Picture #1, you can see the input conditioning board attached normally. The board fits into a punched sheet metal slot and is secured via the 1/4" guitar jack. The board fits fairly deep into the slot. Picture #2 is the same board pulled out of the mounting slot. What you see is an electrolytic capacitor towards the top of the board and some exposed circuit pads. I believe this circuitry is the culprit for cutting in and out. Picture #3 shows my current 'fix' for this: some cheapo electrical tape that is wrapping all of the offending circuitry. I have had this in place now for several weeks with no issues.
The reason I believe this is a design flaw is because it relies on several tolerances of the Helix enclosure to be correct. As an example, the main chassis needs to align correctly with the front bezel of the Helix. Another example would be how well the punched sheet metal slot tab is bent inwards. Because the input board is only secured via the guitar jack connector, there is room for the board to move depending on various factors.
This would explain why some folks have this issue and others do not: it all comes down to how your unit was assembled. It also explains why folks notice this issue when they are playing 'hard'. Vibration of the Helix unit can translate into the input board vibrating and having quick 'shorts' against the metal chassis slot. My Helix is located right next to a powered speaker, so it is not surprising this happened if my theory is correct.
As per my previous post, I will keep y'all posted.