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Hmm. Then you may have just about exhausted my long distance electrical diagnostic ability. Horns are normally pretty simple but yours is temperamental. It's got to be some sort of break in one of the circuit segments. Switch to ground, switch to relay, relay itself, battery to fusible link, fusible link itself, link to fuse, fuse itself, fuse to relay, relay to horn, horn to ground. It's like the relay isn't triggering when the horn switch grounds out. I think I would try to get that relay to trigger through other means. Like a test wire to ground at the relay box? If that works then you pretty much know it's between the relay and the steering wheel.
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