My purpose of this project is minimum change of re-wiring to improve car.

 

 

If you want to re-wire everything,..... yeah, it's nice to do so. 

I defer to some who is willing to do so :-)

On 11/14/2014 at 10:13 AM, Zed Head said:

I notice that nobody has a relay between the headlight power switch and the fuse box fuses EDIT - as another option.  The switch is the part that tends to get pitted and hot and cause the solder joint to break.

 

If you are using relays to power the headlights, then the current passing through the switch is only enough to trigger the relays, typically 150-200 mA. You can replace the stock 10A fuses with 2A fuses if you wish. Adding another relay for that load is redundant.

My suggestion is that the relay at the fusebox is the only relay.  Not an additional relay.  Full power still passes through the dimmer switch/ground.  But only enough to power the relay passes through the weak switch on top of the column.  

Simple, easy to apply, gets rid of the main problem.