Update:
Last Friday (12/27) I started to follow Brodie's lead and finally install a BlueSea and re-wire the Kristas to that, but in the middle of it I again asked myself why did the lights work fine the first year, and then at least for awhile every time I disconnected the battery? (the first time in Oct '12 for the bench test and then Nov '13 w/ the new battery).
I had a long conversation with Glenn at Clearwater - what a great guy, 2 years out of warranty and his words were "come on by, we'll make it right". He was not too excited about not wiring per the install instructions straight to the battery, even tho it seems to be working for Brodie.
So I stopped the fuse box install and did the following:
1 - moved the red turn on wire to another switched-on power source (no logic to doing that)
2 - cleaned the headlight connectors (they were dirty/corroding but otherwise no logic to doing that either)
3 - replaced the ring connector for the negative lead to the battery from the Kristas
4 - cleaned the battery ground wire at both ends (logic here is past car experience on weak grounds creating odd issues)
Just a few night rides since then with no flashing.
I had set up an appt w/ Glenn Friday (1/3) afternoon but called to say there were (currently) no symptoms and we shouldn't waste anyone's time, but when "Glenn" called back it was Brodie - who had come out to help because he was curious! So left work to go visit, at which point a bit of standing around and discussing ensued, some voltage tests of the lights, and an idea to isolate the high beam wire from the rest of the system w/ a switch. Since there are currently no symptoms, we decided to hold off on that diagnostic move until (if, dammit) the flashing re-occurs.
Is it possible that improving the ground connection (it was never obviously bad) has been the problem all along? If the flashing returns, I think I'll clean and re-connect the neg terminal and only do that one single thing.
Will continue to report as warranted and many thanks to all who have weighed in to help, especially Brodie!