I'm currently rebuilding the climate box in my neighbor's '86 Syncro, and found that the blower resistor pack had gotten hot enough to blister the plastic housing--pretty scary.  Since the resistor checks out as within spec, I traced the wires back to the switch and the ground crowns.  Both were found to have melted wires.  It looks like the crowns had rusted due to a leaking windshield, which created extra resistance in the circuit.  I'm replacing the crowns, but also will be relocating high amperage grounds (e.g. heater blower, radiator fan, etc.) to their own dedicated source below the dash.  I may now consider the relays as an additional protection in the circuit, since the owner brought me a replacement blower that looks a lot like the version Alistair is using.

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> On Mar 26, 2015, at 4:33 AM, kenneth wilford (Van-Again) <kenwilfy@COMCAST.NET> wrote:
> 
> Alustair you might want to put a some relays in the system to unload the
> blower fan switch.  That fan is more powerful than the stock dash one so it
> will pull more amps.  Don't want to have a melted fan switch.  Everything
> else looks good.
> 
> Ken
>> On Mar 25, 2015 4:14 PM, "Alistair Bell" <albell@shaw.ca> wrote:
>> 
>> Posted some bumpf about my neighbour's 85 doka. It's worth looking at just
>> to see the nice colour choice he made with his repaint.
>> 
>> 
>> https://shufti.wordpress.com/2015/03/25/vanagon-85-doka/
>> 
>> Alistair
>>