Right away , go take the spare relay out of the SD , open it up and POLISH the contacts as the ones you scrubbed with the emery board , are arcing as you read this and will fail again ere long .
Whenever you're working on electrical contacts , POLISHING them is the only proper way the clean them up .
Sand paper , emery boars , files etc. leave too rough a surface , one that promotes arcing and rapid wear .
-Nate
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