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Sounds like points inside relay have a burnt place on them. Why that happens I don't know, other than maybe to many volts, ( amps ), to it. Pry the cap part off of relay, sand or file the points, (contact area). Then see what happens. This has fixed the non blinking, (stuck on) turn signal issue for me many times years back. I've not dealt with it happening to headlights though.
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