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I don't know that I'd call it a bad design, just one that fit the build budget. I'm sure it worked great when it was brand new, all the connections were clean and tight, etc. I don't think any auto manufacture builds their product to run forever, meet all possible demands, etc. They build them...

LMC, and others, sell a headlight harness that uses relays to provide the power to the headlights directly from the battery, thus taking the load off the headlight fuse and circuit. You can also make one yourself.

Is it just me, or does it look like your 12v buss is being fed from the 24v buss? I don't see the wire that normally comes off the front battery positive to the rear battery negative dog bone cable that runs to the 12v buss block. In the picture, it appears the ammeter is connected to the 24v...

Read the -20 TM? :-P

I believe that the purpose of the diodes on the back of the various relays is to absorb the voltage produced in the relays coil when the relay is released, preventing this voltage "spike" from causing interference in the radio equipment. I doubt they are there on a civi CUCV equivalent vehicle...

You may be able to get to the horn just by removing the headlight trim on the driver's side.

It usually comes down to dirty contacts in various places and 25+ year old wiring that may have corrosion inside the insulation. The system wasn't that great to begin with, as most of the time "good enough" is the penny-pinchers phrase of the day. You could take the time to clean every...