I've seen a number of melted things with the incandescent bulbs. My fix is to swap out the bulbs for an LED with a 270 ohm resistor in series. It drops the power dissipation to a fraction of the bulb's heat and totally solves this problem. Not only that, but the LED's look much better as headlights. I get a lot of units in with a request to upgrade to LED lighting, and nothing is melted on those.
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