hI guys I figure i will update you and ask for more help.
I am working on my 1984 full westy with a bostig conversion ( 60,000
kms on the conversion)
it has a cluster from a 91 carat with tach.
and jay brown bright light relays

i have a power probe 3 wire tester ;) this tester is awesome. you plug
it into your lighter or hook it directly to the battery. when you
touch a wire it tells you wether it's ground or power..

SYMPTOMS:   key in ignition but not on, turn headlight switch on and
it's as if you turned the key on.
                            if the van is running and i turn my
headlight switch on the  the tach needle drops and the lights flash
like i just turned the key on.

trial and era: I have checked all the grounds at the ground stars/
spiders under the dash above the fuse panel. they all check out fine!
                         I have tried a brand spanking new electrical
portion of the ignition switch, and a few used ones. none helped
                         I has ground at most of the terminals on the
fuse panel when the key is off, i don't think this is normal??? is it?
( when key is on it switch's to power )

thoughts:      I don't think there should be ground on my fuse panel

                        I am stumped..

                        any suggestions ?? any other place to check ,
relays to try? ANYTHING?????

thanks
Jay