I don't disagree with Whiteout's suggestion of OEM ballasts, but you've already gone through a bunch, including Hella, which are OEM on some cars, I believe.
So, I'm going to agree with the wiring re-do. Start from scratch. Get a $15 harness and use it. Direct connect to battery should greatly reduce any problems caused by power fluctuations in your system. If you haven't yet, check your alternator. Not sure what the dual-battery setup does to it, but if your voltage goes up down with revs you might need to isolate your systems better.
Don't know what else to tell you. Good luck.
So, I'm going to agree with the wiring re-do. Start from scratch. Get a $15 harness and use it. Direct connect to battery should greatly reduce any problems caused by power fluctuations in your system. If you haven't yet, check your alternator. Not sure what the dual-battery setup does to it, but if your voltage goes up down with revs you might need to isolate your systems better.
Don't know what else to tell you. Good luck.