So here is what I've done... as I was getting ready to start installing the relay system I found that 1/2 of the strands of the red wire weren't attached to the metal contact within the headlight connector causing a heat buildup as the power was getting to the switch. I slid a small screwdriver blade into the contact and pushed the little barb that holds the contact in place and slid it out. I clipped and re-soldered the red wire contact and re-inserted it back into the connector. I also cleaned all the other contacts in the connector with emery cloth and contact spray. The lights work great with no intermittency or heat in the switch, even with halogen high beams on. If I have trouble in the future i'll then install the Relay system but Chevy designed a switch that worked with the lighting system... and it works.
Thanks all...
now on to the Gas Gauge issues...
