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Same here , aftermaket lenses with H4 bulbs used in my RHD conversion.
Have had frequent probs with connector getting hot.Have left rubber boots off to aid cooling.
I haven't installed my light housings yet but I did get them in about a few weeks ago. I just ordered the FSM a few mins ago so that should help with any problems I might have. I got alot of information from alot of the guys on how to take the lights apart in one of my previous posts. I would recommend to keep the lights to something similar in wattage to keep from melting the wires. Good luck on everything and if I can get my butt in gear I will hopefully have mine installed and can give you some first hand information. I may end up having to ask you for details at my pace though.
By headlight conversion, you mean from sealed headlamps??? I've been using Bosch headlights with 100/80 watt bulbs for at least 8 years now with no problems at all. Lots more light, if you want higher wattages you will have to beef up the wiring to the headlights. The stock wiring can not handle it.