Thanks for your responses guys! I sure am Down Under in sunny Sydney! I've checked the earths and they are rock solid! One of the lenses internals has some slight surface rust but not on the reflective surface, mor on the front face as it comes out of the "dish". I have heard that it helps if you re-wire from the bulbs back to the relay as the factory wiring is a little dicky but to be honest the wiring looks in great condition and a decent enough size. Perhaps it needs to be a bigger cable to reduce the voltage drop? This sounds like a pin in the a&^e job thou..... I've taken the acrylic protectors off and cleaned them as well as the glass, not real dirty but trying everything. Is it possible that the relay could be getting some build-up and replacing would help or am a clutching at straws for a plug-and-play fix?