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I sanded my headlight and fog light relays with 320 grit until the grime was gone and the shine returned, but it doesn't appear to make a difference. My take at this point is that the relays just age and lose their efficiency with time, leading them to run hot regardless whether they are reconditioned or not... not that there is really anything to recondition in the headlight relay (much more basic than the fuel relay with only two tiny solder points).
crud, I guess I'll have to pull the board yet again and go completely nuts on all the elements.
On a sidenote, I was amazed to discover that the headlight relay uses two different metals for the connectors... copper for two and brass or something else for the other three.
-rt
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