1.5 brown wire in lt. front harness is hot to horns? With no connection to connector?

Uh, the brown wire should run through the plastic connector, but if it doesn't that's okay as long as it does touch anything. 'Cause yeah, it's "hot" all the time.

American cars don't have headlight signalling relay and associated black to terminal 3, right?

American VOLVOS don't. I don't remember much about the detroit iron i've played with

Only relay on left fender paneI have is for reverse lights.

Yes. US market, like you said.

All front grounds are local to the radiator support. I gotta clean and treat them tonite.

Well, there is better hole down and to the side of rad supports but maybe the head of the screw has been stripped. Won't bother me if you drill:o)

One thing about it, I will know the electrical system pretty well when I get done!!

Abso!

Shayne

P.S.
The Stainless moldings at the base of the widows are a PITA to take off!!!!

Uh huh. Work from the inside. Pry up and out. You'll have to get the glass to lower far enough first. With the door panel off, gently bend the window stop in the bottom of the door so you can roll the glass down a bit further...not too far or you'll be teaching yourself how to put the cable back on the pulleys.