Headlight harness constantly burning them

ok so I have the aftermarket ebay one peices and I have been burning up harness after harness every couple weeks. This has been goin on for months and I am sick of it so please help me to save some money.

These are the details. The factory harness hooks up to a secondary harness that is between the stock harness and the actual bulb. The secondary harness consists of about 6 inches of wire with female/male wire connects. I did this awhile ago because it was easier to hook up a new harness on the bulb side when it burnt up every few weeks. As I said the part of the secondary harness that connects to the bulb is what is burning up. It is melting or something and turning black and burnt or even sometimes they look like the plastic just melts away from the metal prongs. The end that connects to the bulb are “high temp” harness from stores like autozone etc. every few weeks they burn up.

The bulbs I am using are Luminics 5500k titantium white 9007. The bulbs are supposed to be stock wattage though so I didn’t think that would be the problem. Ground is also not a problem. Once to test I grounded the bulbs ground wire straight to the chassis before and it still melted the harness.

I have some luminics jdm yellow fogs that have NEVER given me a problem and they are the same wattage as the headlights so I am confused. I would hate to do this but If i can’t resolve this I am going to put my old “ricer blue” 9007 bulbs back in. atleast they didn’t give me any problems.

help quickly please. I need to solve this before I go to work today.

If the wires are “burning”, [insulation melting] only at the end of the harness, where they are connected to the bulb, it is a connection problem, resistance at the connection points is producing heat, or it is heat off the bulb itself.

If there was a short, fuses would blow.
You have not replaced the fuses with higher amperage ones have you?

The same goes for too much load, bulb wattage higher then wiring can handle.

In both the above cases the wires would get hot along their full length and the fuses would blow.

Question, about the wire that is used to make the “secondary harness” is it the same gauge as the cars stock harness wire?:hmm:94

No fuses ever blew stock ratings still in. also sometimes the wires have looked burnt but only near the harness where it comes out. sorry i didnt clarify what is burning really is the plastic of the harness that surrounds the 3 connector points that the bulb slides into. the wire in the secondary harness is one step higher than stock. 14 or 16 gauge i think.

That definitely sounds like a connection/contact problem,
poor connection = resistance, resistance = heat:cross:94

Maybe you can use bulb grease?