melting headlight switch on 4000

[dcrismon at mail.slip.net]

I have had my 1987 4000CS Quattro since 1991. Just in the last year I have had three headlight switches melt. I have noticed conversation about this topic before, but I can't find a solution in the archives. Has anyone found a fix? 
I have gone to salvage yards and clipped out the male and female parts of the switch and reinstalled them in my car each time. Once the switch went 4 months before meltdown, another one much sooner. Some of the switches found in the salvage yards show some melting too.
The previous owner did try to run 80/100 watt bulbs in this car without any other modification. Has that caused a problem? My mechanic who is usually knowledgable can only assume a loose connection, but will try to check all the grounds and relays this time. Any suggestions? I would really appreciate the help.

David in Louisville

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