for some reason VW's just suck when it comes to headlight systems. I've had a problem with every Audi and VW I've owned so I almost always do this, even with stock voltage bulbs. I do things a little different. I only use 14g wire from the relays to to lights. As long as the relay is kept close the voltage drop is not a problem. I also solder as many connections as possible, including those on the relay itself. Takes a little more time this way but less reliability problems. My experience is that it's more likely that a wire will come loss or corrode than a relay will go bad and need to be desoldered for replacement. I also lower the amperage of the stock fuse so it will be more in line with the actual reguirements of the relay system instead of a headlight. again thanks for the post and the great pictures. Just proves what I've been seeing for years.

1998.5 1.8TqM sport @ 150,000 and counting...