Re: Dim Headlights on 40:
I agree, seems like a bad headlight switch if there is 1+ volt drop through the switch. But I don't think that explains the other symptoms, which seems like a whole-car ground problem.
OP said " At battery I have new woven ground to firewall and then another from there to nut on head" I would try re-doing that connection at the firewall, trying to get the best metal-to-metal contact there.
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