My ignition switch keeps melting! Yikes

[SpeedySpider]

So when I first got my '81 spider this past July, I bent the keys almost to the point of breaking because I needed a new lock. Sooo me, being the procrastinator I am, didn't go out and buy a new one yet. I took out the guts of the ignition switch and just used it to start my car so I could keep the keys in the lock for steering 24/7. Lol I know this is bad. ANYWAY, the plastics of the switch completely melted to bits on me one day, I never realized it had been heating up. So after that episode I installed those electrical push button type switches to start my car temporarily until I got the ignition switch in the mail (currently on the way) ... And that just melted too lol. BUT I figured out that it only heats up when I turn the headlights on, it must be drawing too much power somehow. I'm not sure if it was doing this when I got the car or not but I have not messed with any wiring since so it is possible. Also I hardly used the headlights until lately as it is dark earlier now. The guy who had the car before me installed a CD player and possibly a manual motor fan switch ( does not look stock), so I'm not sure if that has anything to do with anything lol, any suggestions?? I don't wanna install the new ignition switch yet if it's just gonna melt!

[azruss]

If you have an abnormal draw, one of the wires out of the back of the switch should be melting as well.

[SpeedySpider]

Hey I'm not sure what you mean, I assumed that's why the switch is melting, cause of the wires heating up. I have no idea lol I don't know about this stuff

[vandor]

There is a white plastic connector 7-8" away from the ignition switch. It is common for the metal connectors inside to have poor connection, and when that happens, they heat up. When this happens the while plastic connector turns brown or melts. I assume the wires get hot too, which may be what melted your temporary switches.
It would be a good idea to add headlight relays, and maybe even some to the ignition switch.

[GeorgeT]

BUT I figured out that it only heats up when I turn the headlights on, it must be drawing too much power somehow.

This was a design flaw which routes full headlight amperage through the ignition switch, the headlight switch on the dash and the column switch for high/low beams and ignition switch failures are not uncommon. Do your self a favor and install headlight relays and reduce the electrical load on these components and get brighter lights as a bonus.

[4uall]

this might help

http://www.mirafiori.com/faq/content/relays.htm

http://www.mirafiori.com/faq/content/el ... estore.htm

[SpeedySpider]

Awesome much thanks to all of u that helps bunches, Sounds like relays are the answer and I'll check out the white plastic connector as well
& thanks for the links!