After we reassembled my son's 1979 Subaru Brat he blew a fuse on his headlights. This is the 25 amp fuse on the very bottom of the fuse block. We replaced it thinking the fuse just went bad, This weekend while I was in his car I noticed a pile of blown fuses on the drivers floor so I asked him if he was still blowing fuses and he said "yeah, a couple times" So I started trying to problem solve it. I cleaned everything up and made sure the fuse had, what appeared to be, good contact. When I turned the lights on they worked fine but negative side (left side as you face it) got hotter than hell. It would get hot enough you did not want to touch it.
The plastic fuse block has also been burnt in the past because it was all melted. I pulled both wires off the back of the block, replaced the female ends and connected them directly to a new blade style fuse and bypassed the fuse block all together. I still have a fuse in it, I just connected the female ends right onto the blades of the newer style fuse. It seems to be working better. The fuse still gets "warm". you can hold it and it is not uncomfortable but you can tell it has heated up a little.
I know there is a ground near the battery for the lights and it is clean and tight.
ANY IDEAS OR HELPFUL TIPS?