I just got done with the relay set up (Thanks to the tech article.) It took me about 4 hours total (I'm a bit meticulous). I tested the lights in high and low. No more flashing headlights! I felt the wires at the dimmer switch and felt the headlight switch and no sign of heat. I had the lights on for about 30 minutes.

Heep70, are you running 55/60 watt H4's? I'm running 80/100 watt H4's and that may be the reason for the extra juice.

 

I am running the 80/100 Xenon blue white bulbs.

I am not real hip with electrical. What exactly does the relay set up do?

 

The idea of the relay is to "divert" the full voltage to your headlights, instead of having the voltage drop by being routed from the battery, through the headlight switch and dimmer switch to your headlights. The relays were pretty cheap ($5 each). I had wire and connectors already. The biggest ticket item was the fuse block. I went and bought a Blue Sea marine type fuse block with cover, $25. You can just go with a simple inline fuse holder (maybe $3 each). Not a hard thing to install. If your lights start doing the "flash", then you know a relay may be the solution. Maybe your new headlight switch can handle the heat better. I have no idea how old mine is.
The regular 80/100 H4's are probably not as bright as the xenons.

 

I finally read the whole tech article on "Whiter Whites, Brighter Brights - by Steve Delanty". I understand now what is going on.

My headlamps used to be real dim to the point that if it was to start raining at night while I was driving I could not see the road in front of me. No lie. The way I fixed it was I took out the old charging system (wires, alt, and regulator) and replace it with a 70amp onewire alt, new heaver gauge wire, and a new headlamp switch. After that with the old headlamps I could see for a long ways. So I am thinking I may have solved the low voltage problem with a different method. Today I am going to check the current to the headlamp just to see what it is getting.

I will keep in the back of my head that if I see a flicker I will know what the problem is and how to fix it.

I had a somewhat similar problem when I installed my MSD dist. It burned out on me in a months time. I did some checking with the maker and found out that the dist would die if the voltage was under 12.5 or over 15.5volts. I checked the pos dist wire and found that it was only releasing 10.5volts and that the wire from the key to the dist was resistor wire. I spliced in a new wire and haven't had a problem.