Hi Guys
I have encountered terminal posts on light switches discoloured and wiring insulation charred due to heat from high resistance terminations on the light switch. The standard method of termination leaves a lot to be desired and can easily end up with poor terminations possibly leading to fire. I have overcome this problem by screwing 4 mm. male spades to the switch and crimping 4 mm. female spades to the wires. Makes for much better connections which are easily removed and replaced. One of these female spades with red pre-insulation can be seen in my first photo in the thread 'green light above ignition key'.
Bob
A good idea applicable to early car, the later toggle switches had spade terminals anyway - primarily because it's quicker and easier (and therefore cheaper) to build.
Have you increased the current drawn through the switch by fitting stronger or more headlights/lights or has it happened due to lack of contact at the terminals.
Have seen problems with other switches so had a look at mine and decided to make the mod to eliminate potential fire hazzard.
Have fitted halogen lamps with slightly more current drain as well.
Bob
