Ok here is the problem. Installed my ACA housings and converted the low beams to HID but left the high beams Halogen, though I am using an HIR bulb.
Also installed HID fog lights to match the low beams and the LED corner lights and strip (from Radioflyer). Everything was working fine for the past three weeks. I also installed the resistor from JW Motorsports to ensure that the buckets would function properly, as well as the Hi-4 harness from Radioflyer and a harness I copied from Toque’s web site to engage the fogs when the highs and lows are on.

Yesterday the passenger side low beam would not light. I did the following:

First disconnected the resistor since it is on the passenger side and connected the ballast for the low beam directly to the OEM socket. No change, low beam passenger side still not working.

Then disconnected the ballast on that side and replaced it with another Ballast (from a HID conversion kit for the high beams which I decided not to use since the high beams on the ACA are not a projector lens). The low beam bulb now worked.

Reconnected the resistor to the new ballast and the bulb still functioned and the buckets lowered again without having to turn on the highs.

Then today the same low beam is again not functioning. I doubt I have two defective ballast, and the drivers side still has no issues nor do the fogs and they all use the same type ballast.

What would cause me to keep blowing ballasts if in fact that is what is happening? Or does anyone have any other ideas as to what may be wrong?

Any help would be greatly appreciated. Also the vendor for all the HID kits is CorvetteMods who has been great. I emailed them today when I thought the issue was just the first ballast and they immediately responded that they would replace it free of charge. I just don’t want to continue to throw another ballast on there if for some reason I keep blowing them.
Also, I did not run dedicated harnesses for each kit from the battery, but not sure that would cure this issue since all the other HID bulbs are working fine. Thanks in advance.

 

I am actually of the opinion that this is probably your issue. A lot of C5s don't like HID's through stock wiring. It's really not uncommon to have one light flickering or off while the other 1 (or three) remain lit. Also, I had this issue on my C5 before installing the relay harness as did a friend of mine around here and for both of us it was the passenger low beam that failed to light consistently after a few weeks of use.

Let's close the loop on the troubleshooting... Take one of the "blown" ballasts and connect it to the driver's side (the one that is currently working). If the driver's side bulb lights then your ballast is fine and a battery relay harness will likely alleviate your issue. If it does not light then post back up...

 

I took the "blown" ballast I replaced and connected a spare bulb I had to it, then ran leads to a 12 volt battery. The bulb lit up fine. So it seems you are probably correct about the harness being the resolution. It just threw me that only one side would have this issue, and that the replacement ballast worked for a while before seemingly failing.
I have a relay harness set up to go and will install it for the low beams. My only concern is that the harness is wired to use the passenger side OEM socket as the trigger for both passenger and drivers side low beams. Hopefully this will not be an issue as it is the passenger side that is having the problem. Thanks for your insight.