Instead of going the spendy H4 European route I plan to replace the 9004
65/45W bulbs with the Hella 9004 100/80W bulbs. I am concern if the
increased heat from the higher wattage bulb will a)risk cracking the
lense housing b)risk melting the lamp socket or the wiring to it.

Here is the links to the Hella 9004 100/80W bulbs at Susquehanna
Motorsports. They also has one with Xenon gas to provide whiter light
(same light output):

http://www.rallylights.com/hella/9004.asp

They also has a very detailed Bulb Help page:
http://www.rallylights.com/hella/bulb_help.htm

Anyone has experience to share with this configuration over extended
time in hot climate?

I will add the relay and the change the fuse size for the increased
current.

Thanks in advance

- Vince

http://gipsyflies.home.comcast.net
1989 Vanagon GL Camper
1993 Mazda Miata
1996 Land Rover Discovery
2005 Mini Cooper S (almost here)