Don't overlook the foot dimmer switch, I've seen several issues that ended up being in that area 
I swapped that foot dimmer out since I had it and it was cheap.
I did notice that the plastic plug part has degraded a bit.....maybe some melting or maybe just crud on one terminal which is also the one that has the broken/messed up plastic part....I cleaned it up best I could and reassembled.....no issues so far.....
I am thinking relays would be a great idea....
Getting some info from Crackdback....want to make sure its completely plug and play etc.....I hate wiring. I can do itwhen I need to but i hate it. LOL
I am only running stock headlights but I imagine it would be safer to run them through a relay etc.....
Will the relay setup take the load off that dimmer too then?
