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Most of the lighting problems I had were due to bad grounds. The ground wires connect to the marker light frames with 30-year-old rusted #10 screws, and the headlights are connected to the marker light grounds. Everything has a wire in a car with a plastic body!
Just to clear up a point, I have a Citicar with a Terrell differential (motor in parallel with the axle) and room for 8 batteries under the seat. I use six 8v batteries (48v) and the other space is used by the controller, DC/DC and accessory battery. I can go up to 24 miles (or so) but generally limit it to 15 to not discharge the batteries too deeply.
With your 5-battery setup, I would expect you to be able to get 20 miles at most, but on a daily basis you probably shouldn't go more than 10-12 miles before charging. Biggest problem is that when you have more voltage, you tend to drive faster which eats up the amps...
You can take the windows to a boat canvas shop to have the plastic replaced - much easier to see with new plastic as opposed to the sun-faded semi translucent (and cracked) stuff I had with the original ones.
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