>         circuit is a 14.4V battery powering an LM2594M
> through a FDN5618P p-channel MOSFET and a 3R9 0805
> resistor.

Rude possible solution:
Slug the FET turn on signal so it rises slowly enough for the FET to still
be at high resistance during capacitor precharging. May require one C added
and possibly an R & a C. Not a nice solution - would be better to fix the
problem but ....


        RM

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