I fixed the Insight headlight switch, but I did not add a relay. After looking at the crimp and wire that were damaged, it was easy to see that they were over heated. Not a surprise since the plastic around the pin in the headlight switch were melted. Here is a pic of the damaged crimp and wire after removal from the Insight wiring harness. This pic shows that the copper wire discolored from over heating. It’s very easy to see with the naked eye. Not sure if the pic shows it well enough. But the insulation is definitely darker nearest to the crimp end of the wire. The copper wire discolors and the connection to the crimp gets worse.

Here is what I thought would help keep the connection in better condition as it ages. I soldered it. This will take out the ability of the wire to affect the connection. We’ll see how long it lasts.