So I've been chasing an issue with my '84 Carrera's headlight circuit - the yellow wire under the dash has been getting hot to the touch when the lights are on. Figured it was time for a headlight relay kit to reduce the load on the switch circuit.
But here's where it gets interesting: pulled the front fuse panel cover to install the relay, and what do I find? Completely bare wire on the license plate lamp circuit, plus melted sheathing on other wires in that same circuit. Not great.
Double-checked the bulbs - they're correct spec (12v 5w). Lamp housings and wiring at the rear are clean, no corrosion or moisture issues. The wire insulation is only melted within an inch or two of the fuse panel itself, rest of the loom looks good from what I can see.
Here's what's puzzling me: this is all isolated by the fuse panel, and both the fuse and wire connections looked solid. What would cause localized heat damage right at the panel like this? Drawing too much current somewhere? Bad connection creating resistance even though it looked tight?
Anyone else dealt with something similar?
(Zip ties in second photo are so that I could group wires before pulling panel to inspect behind it)
