>I unplugged the switch and somehow it had
>overheated and melted the plastic on the back of the switch which
cocked the
>plug on the switch so it did not make proper contact.
> I really think the solution to the headlight
>switch problem (and also a way to get brighter headlights) would be to
install
>a headlight relay.  This will take the load off of the switch (which
obviously
>can't handle it) and put it on the relay (which is made to take the
current).

Headlamp switches often overheat as the result of corrosion-induced
resistance on the switch contacts. Over time enough resistance builds up
to cause not only a significant voltage drop but also generate enough
heat to deform the plastic switch housing. This phenomena can also occur
on a relay--anywhere you have a relatively high current passing through
a spade lug connection. The best preventative fix is to clean the spade
lug connections and ensure they provide a good electrical connection.

MM

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