In researching the electrical load and relay problem I found this ...

https://sites.google.com/site/vanagonheadlightrelays/home

It describes the problem I am having to a T.  Has anyone used this kit?

Vanagon Headlight Relays - Google<https://sites.google.com/site/vanagonheadlightrelays/home>
sites.google.com
The Problem: If you have driven your Vanagon at night more than a couple times, you've probably noticed that the performance of the stock headlight system falls somewhere between a bit inadequate and downright dangerous.

Dave B.

Boise

________________________________
From: dbeierl@gmail.com <dbeierl@gmail.com> on behalf of David Beierl <dbeierl@attglobal.net>
Sent: Sunday, June 24, 2018 7:54:59 PM
To: David Boan
Cc: vanagonlist a
Subject: Re: Electrical Gremlin Back

I added the GoWesty SA kit, the one with the 4 headlight grill, not the high power kit, which did not come with additional relays.  I did the high power kit, with the additional relay, many years ago. I will dig into this further as clearly the increased amps from this and other accessories is causing a problem.

If the relays are installed correctly, the only current passing through the dimmer switch (and ignition and headlight switches) will be the 200 mA or so needed by one or the other of the relay coils.  400 mA if both are operating (low beams on and stalk pulled).  This will not account for the melting you see on the dimmer switch.

Yrs,
d