First thing that crossed me mind also Stu. I must have run the whole sequance through a hundred times and there is no way that the fix could have affected the main head light contacts. If you takie-look-see, I didn't break down the main part of the switch, just the dimmer section. The main body is a little more dificult to disassemble and still reassemble. Maybe I should have taken it ALL apart and checked the head light contacts. If the dimmer conections were corroded then it's entirely probable that the main contacts have some corosion. They are sealed up a little better than the reostadt so I gambled on them being OK. Lights are all nice and bright so there didn't seem to be any voltage dropping across a bad contact.
It only opened on me that one time and I've been running round with the lights on even in the day time to try and duplicate it, but nota. Sure shakes your confidance.
I guess I'll have to carry a half dozen flashlights and roll of duct tape around in case it happens again some time.
Denny Graham
Sandwich, IL

p.s. Restored Dash Dimmer works perfect by the way!

Denny G
Sandwich, IL