New to fixkick/headlight problem

[KickDaily]

Hey guys, just signed up and from Vancouver Island. Been driving my 93 kick as a daily for over a year now, done every mod/repair to it myself and am on a tight budget now that I have a mortgage after I built myself a house. Only light stuff so far nothing major, just want to get it tip top before I start building it up as a daily commuter/weekend warrior.

What I have is a 93 kick, 2 door, 5 speed, removable hard top 4x4 with manual hubs and is in prime shape too. No rust, clean in and out, spotless.

My current problem is I keep blowing out both headlight bulbs. Was subtle at first but now is instant. Headlamps are mounted solid, no vibrations, bulb harnesses aren't burnt, under hood green(40) fuse appears fine as well as both blue(15) fuses under dash. Installed a voltmeter gauge wired into cd player switch wire and reads 14.5 when running. Same altenator and battery since I purchaced over a year ago. I've also tried 3 different name brand bulbs at different price ranges.
Apparently is a semi common problem but can't seem to find anything informative on the net. Has anyone else experienced this?
Any tips would be greatly appreciated.

[fixkick]

welcome. Daily
nice find, clean no rust .
there are only these ways, i think
touching the bulb glass, no finger prints allowed
water flooding in side, nah, you'd see that.

wrong p/n bulb 9004 i think is correct 55watt, $9 at walmart $1.73 at rockauto "philips"
voltage spikes
or insane vibration

it might be bad battery cables and at the same time, this cause the alternator inside regulator to go nuts. it should not but can..
but you would see the lamp flare bight, a dead givaway.
can i assume the fuse box on the right fender, (underside) is free from green corrosion, (common)


http://www.rockauto.com/catalog/raframec...ttype=2796

[KickDaily]

Hey fixkick, thanx for the reply.
I know all about the no touching the bulb deal, definitely not that.
No water, proper bulbs, cables and battery are mint, no corrosion.
Everything is tight, no vibrations.

I'm assuming it's none of the simply obvious stuff.
Perhaps a bad relay or something maybe?

[fixkick]

and the bulb explodes. but youd have seen that.
just too much voltage and or vibration.

had a VReg go bad once, driving, and it blew ever lamp in car out. all of them. i was really angry that day, in the dark and in a bad neighbor hood. (mech, reg, then)
i drove behind a SEMI truck close. till i got home. 2am. I was like glued to him.

try the off the shelf blubs at walmart. they are ok.