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You do not connect the wires after cutting the diode out. You simply remove it and tape up the exposed wires.

Excellent! So, lets fix that horn circuit issue next. I suggest we simply eliminate the diode and the suppressor. Then see if the horn works. The suppressor is near the horn(behind the grille, simply unplug it and plug the wire directly onto the horn. The diode, you need to identify your...

Let's keep this thread on track and discuss that topic in the other threads dedicated to that topic. Adding a headlight relay kit changes the location of the source of voltage for the headlights, thereby improving their performance, it does not identify and eliminate short circuited components...

Thanks but, my theory is based on what you and others have posted. I just studied what was available to me(on this site). So, Thank you . I could be all wrong... But it is possible and does look like the issue in this case!

Let me explain a bit of logic on this topic. I agree that doing the headlight relay modification will eliminate a large portion of the load on this circuit, thereby resolving the "effect", but not the problem. Think about this, the headlight circuit/load has not changed since the truck was...

Yes it does. I'm suspecting your diode and suppressor and maybe even your horn, are all bad. There is also a relay in this circuit that may be suspect. We can work on that next. Let's get some run time on it with the horn fuse out, and be sure we've pinned it down to that circuit(as the issue).

Yes

Is your horn fuse out? If not, remove it and see if you still have the problem with the fuse getting hot.

Doing that relay conversion does not repair or pinpoint the original problem. If it is a bad contact in the fuse socket or in the firewall/harness assemby, your still using that bad curcuitry, and simply releiving most of it's load. My comment about the horn fuse, is along a whole other line...

It might be intersting to use an IR gun, to check or monitor this heat issue.

Does your horn function properly? Just for fun, try removing your 15 amp horn fuse and see if your 30 amp fuse still melts with your lights on.(I have a theory) If you think you did not solve the loose fuse connection, maybe you could solder in wires and use a new external(out of the fuse...