[...] Took a kill switch apart recently, it was worn out and mangled, Rusty spring and contacts no longer seated correctly. It LOOKED fine, if a little loose.
You are braver than I am, Phil. I've often been tempted to open that kill switch, just the kill switch. I was afraid it would not survive me flipping of the red lid. I wonder how this can be done without damaging that no doubt over time hardened red lid. Coward, that I am, I've taken refuge in a V-drop measurement the next time I had to open headlamp bucket. Although I can't remember the exact digits on the meter, there was no voltage drop worth mentioning.