[Dave at Pelican Parts]

I don't know what else could be causing that sort of draw. It could even be something that is shorted only when the relay is closed? But the braid is definitely the path from #30 to either 87 or 87a (depending on if the relay is open or closed). It's probably worth it to check how much current is going through them. Though again, I don't remember what they're rated for.

Maybe the braids are corroding and have some real resistance now? That would certainly generate heat.

Metal braids are available in various sizes. It should be possible to get new material and solder it in if you are good with an iron. How permanent the fix is depends on how good the joins are and how much current flows through, of course.

BTW, the cover is either pressed on or glued on to the base of the relay. I have one that the cover is loose on; I can just pull the cover off the relay to see the guts inside. No saw required. You might be able to convince yours to open up the same way instead of sawing them.

--DD