Passengers headlight not always coming on

Some one in the past converted my my headlights to the HID round style. I have been having issues with the passengers side HID not coming back on after I have been driving for awhile. Thought it was the ballast going bad and not turning on after being hot. Replaced both ballast, still have the same problem. Replaced both HID bulbs, still have the same problem. Found the 15 amp breaker in the front drivers compartment (for the headlights) was a bit weak. Replaced the breaker, still have the same problem.
I have checked all the wiring I can access and it all looks good. Bumps or jiggling does not effect the light not coming on. Only time the passengers headlight does not come on is after I have been driving for a few hours, then start again in a short period of time. If I turn the headlight breaker off then back on again, the passengers light will restart and work. that leads me to think it's the ballast or lamp getting hot and going bad, BUT I have already replaced those.
Kind of at a loss. Any one have any thoughts on this one?

Chuck