Headlight electrical shorting out / blowing fuse?

[Stonebag]

So I am out of town last night when my left headlight went out. I always knew the connecting on that light was pretty janky because when I bought the car one of the connectors/wire that connects to the headlight was pretty melted somehow. So I went for a quick fix and tried to shake the wire around a little bit to get a connection back so my headlight would come back on and in the process I must of touched the two wires together because i think it shorted out and blew my large headlight fuse (the large one inside the engine compartment fuse box (4g63) along with the small fog lamp and tail lamp fuses).

So i put a new large headlight fuse in and it worked for a 30 minute drive him and all morning but tonight when i turned my car on to come home from work, I turned my headlights on and it blew the fuse again.
Now there is no way it shorted out because there was no exposed wire. I wrapped both connector ends in electrical tape last night and put the headlight in my center console.
Other Info: Voltmeter when lights are on and working and no blown fuse= 13.9 to 14
Voltmeter when headlight fuse is blown= 14.9 top 15

So my question is:
1) Whats blowing this fuse?
2) Why did the wire melt in the first place?

Thanks.

 

[Gasolinebaptism]

It sounds like there was an imperfection in the melted wire you were talking about, and the issue had been growing and growing. Til just recently the resistance on the wire raised high enough to cause malfunction, more heating of the wire to cause furter melting, and a number of things could have happened from there. it sounds like you need a new wire setup for the headlamp.

 

[steele_verus]

If you eliminate the wiring as a problem, try replacing the relay in the fuse box.

 

[Stonebag]

Today I replaced the whole wiring setup in the headlight and replaced the headlight and it works fine now. The only problem is, when I turn on my headlights it instantly blues the 15amp tail running lights fuse every time, so I don't have running lights or dash lights.

Why does it keep blowing that one fuse and not the others? Could it be a bad tail lamp relay? Would that instantly blow the fuse?

 

[Gasolinebaptism]

Well, it can. it depends on how important it is to fix the issue, if you have a little bit of cash, then pop a new relay in, and see if it works.

 

[Stonebag]

$800 fix. 10 hours of labor, the shorting wire kept melting more and more of them.