Eliminating all the wires seemed to eliminate the stock headlight relay, I think this is the problem that CrimsonReign ran into with his set up as well. Note to self and all those that question McV for advice...listen to what he says and just do it even if you think there might be another way, when all is said and done it will be right if you just follow his advice.
I contacted McV Sunday night about my issue and his advice was to run a new wire and circuit because of the draw of the headlight...guess what I ended up doing last night...yep, running a new circuit.
Ran an inline fused (30A) hot wire from the battery to an off road light relay that I could tuck into the stock bucket ($4.99 at O'Riley's), attached the ground to the turn signal ground that is now not being used. Used the other connection to ground the headlight. Used the BLACK/RED that the wiring diagram shows as switch power to the headlight as the switch hot for the relay and then one line out to the headlight.
Now this is funny now, but was NOT funny when it happened. I get the new circuit ran and plug it in and the headlight comes on and then goes right out...WHAT THE *%#@! Stopped to eat dinner because I was really frustrated now. I have 4 bikes tore apart in the garage right now so after dinner I grabbed an H4 bulb out of one of the VLX's and plugged it in. I suppose I might have touched the lamp and got some oil from my grubby hands on it causing it to blow, but what a coincidence. Worked fine.
Owner came and picked it up last night and went for a 60 mile ride, it was good to go. I was working hard to get the bike to him because he is a fireman and is prospecting for the Lawful Son's here in Memphis and today he went on probably a 200 mile run providing transportation escort for the Traveling Vietnam Memorial Wall. He reported back that it worked like a champ and the bike was awesome!
Here is a before and after...crude, these are his pics. I did this bike in stages, we still have a few little things we are going to do like powder coat the wheels red and put whitewall shoes on her this winter some time.