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ntsqd,
The rewiring will be worth it for the peace of mind. As you probably know it is mostly an a-boy problem. I've had circuit breakers in the headlight switch trip open on several occassions and partially melted the connector to the headlight switch on another. None of these cars were rust buckets or otherwise obvious electrical basketcases. All had standard or Halogen sealed beams at the times of failure. In all of the wiring diagrams I've seen, only the A-bodies got 16 gage wire to the headlights. IIRC, everthing else used 14 gage.
On my Grand Wagoneer, I didn't bother with relays because the stock wiring is adaquate for stock wattages. So same experience as you on other vehicles - relay is not needed.
demoman3955 - Most likely H4. H4 is the dual filiment bulb and the Hella H4 housings are sold in the US for motorcycle use.
I think you're missing something here. Hardly any new cars use the headlights most of us are talking about. In fact many have crumby plastic lenses. H4s have been around since the 1960s. Chrysler engineer Scott Harvey considered them practically a neccessity on any rally car. The problem has been that until recent years they only had European approvals for road use. So in the US, a vehicle could be failed for inspection since the lenses did not have DOT markings. A few states actually enforced this, and eventually Hella made a version that was tested and marked DOT.
So if you buy an H4 assembly from a reputable company, there will be no question about whether it will work. It fits the same, uses the same connector and uses the same wattage as the sealed beam it is replacing. The lens will be made of glass and will have either DOT or E-code markings.