> What I have done is get some 8ga wire
> and went
> from the battery direct to behind the grille (install a fuse fuse
> at
> the battery!) then I installed some water proof 30A relays behind the
> grille one for low beam, one for high beam and one for my rallye
> lights.  I used the original headlight connectors to trigger the
> relays and have new 12ga wiring to new terminal housings that plug
> into
> the back of the light.

I did essentially the same thing, except that I have four individual 10ga
runs (HI  & LO, Left & Right) run to relays under the driver's seat where I
have a  6ga jumper to the battery. My first attempt was directly feeding the
substandard wiring under the dash (a la the GoWesty fix), but truth be told,
I could hardly tell the difference! Sure, it was better, but it still wasn't
anything to write home about.  Now, with round Hella H4 reflectors and 120W
yellowstar bulbs on independent 10ga runs, I practically need sunglasses to
drive at night.

--
John Bange
'90 Vanagon - "Geldsauger"