No, read what I wrote, you're making my point. If they were defective from the factory why wasn't there a recall? It's not a great design, I agree. But it works fine.

 

Yeah I read it.... but it's not 'defective' per se.

I bet if it's kept dust free and cooled with a constant stream of air that the thermal breaker wouldn't cycle.

 

Except, the breaker tripping is a symptom of a problem, not the problem. I bet if the grounds and connections are good the current won't spike to begin with, and the breaker won't trip. See where I'm goin' with that?

As mentioned "it takes a while for it to start" i.e. intermittent headlights weren't initially part of the standard equipment package. It's easy to tell that copper wire was considered a semi-precious metal with automakers, using the minimum gauge and barely adequate when new.

Relays are used for this reason, agreed. Even so, corrosion is still why there are so many electrical problems then and now.

 

It would take about 30-40 minutes of headlight use before my switch would go tripping.

 

That is about how long it takes for mine to start flickering.

 

Well I definitely warn against using the LMC relay harness. I would opt to replace the switch.

 

Early on replaced floor and headlight switches in the 64. Been running 30 amp generator and halogen lamps ever since for roughly 20 years, part of that as daily (and nightly) driver, cross country trips, etc. No problems.