That's really strange guys that the bulbs blow ,there is a 2009 Hyundai here that's over 100,000 and never blown a headlight bulb.
When I google blown bulbs it's a common problem as you say.
I would have thought the same as Norm that the Voltage was too high.
One thing someone mentioned was a bad earth as a possible problem.
When I look up causes of blown bulbs I get the following.
There are a few reasons bulbs can blow, the major one being cheaper bulbs. The elements in cheap bulbs are much thinner and any surge of power, however slight, simply breaks them. Always go for more expensive, better quality light bulbs, its cheaper in the long run.
A loose connection in the lamp holder can also cause bulbs to blow. This is because the circuit is not completed as tightly as it could be and the electricity may have cause to "arc" or jump across the contact, rather than simply flowing through it. When this happens it produces more heat in the fitting than is expected or catered for by the bulb, and the bulb can blow.
The same can happen if the spring loaded connection in the bulb holder is slightly loose. This will cause electricity to arc across the contact, cause too much heat and blow the bulb. This can very often be diagnosed by looking at the contact on the bottom of the bulb to see if it is pitted.
Arcing electricity effectively melts the metal it is arcing onto ( This is how arc welding works) so if the bulb contact is being subjected to arcing, tiny little indentations occur, called pitting.
It is sometimes possible, if the live connection in your light switch is a little loose, for this to happen here also. Heat will be generated and it is possible, though very very remote, for the bulb to blow as a result of this.
Hmm I think I would try fitting another relay and make up some earth wires to the globes, I guess it can only be the wiring the light switch
or the globes as long as the voltage isn't too high.
I never touch globes when installing them ,always use a rag to hold the globe.
Very strange as I've also heard of other people not having a problem with the globes .
Cheers
Max.
