Wiring fault on high beam wire burns/frazzles out!!

[Retrostu]

My mate asked me to take a look at his car for him, it's a 85' 1600 cabriolet with s1 body kit ( i know its not a turbo but didnt where else to get the best knowledge base). The heater box motor was not working so i tried his switch on my S1 and all ok i then took my relay (small yellow one nearest the drivers side wing) out and tried in his and the blower started working all ok. I then used another spare relay as i wanted my original back the spare he could keep same as the other in the headlight relay slot all ok lights worked fine but on high beam/flash passing light the brown/yellow wire start to frazzle and burn out. I then changed the headlight relay back to the original one he had and it still did it. I feel really guilty although i have not really done anything. (blower still work though) I hope this dose not sound toooooooooooooo confusing. please any help advice gratefully received.

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