I would check the headlight switch for burnt plug, housing, etc. If it's burnt, replace it. That happened to mine and I did the relay mod and a new switch great lights!!!!!! About a year later the floor switch went bad. haven't had a problem for a few years now.
Ill check the switch to, glad it’s worked out good for you.
Got the dimmer switch in yesterday without tearing the floor up, and there was no rust underneath there which was nice to see. Greased below the switch for good measure.
I’m using 12g wire from the relay to the lights and will be making my own headlight connections with standard 3/8 female plugs.
Couldn’t find a light plug harness with a large enough gauge to want to use, so making one that is heavier duty.
(Maybe I can use the old plug body still with new 12g wire soldered to directly to the plugs.)
I’m going to jump off the harness from each respective wire at the headlight to the plug on the other headlight. High and low beams will be on their own relay of course.
Starting with the harness today (looks like the project will take me a few days as time allows).
Researching where the best place to tie into the factory wiring harness at still, looks like passenger and driver side wiring for the lights come out of separate harnesses.
Going to probably cut the old plugs off at the headlights and tie the relay in from that point for simplicity’s sake, and have a relay on both sides of the engine compartment mounted cleanly.
Might be making this more of a project than necessary but don’t want to have to go back to it twice.