Scott, your getting too good with glass fab work. Getting those edge inserts for the lenses had to be tricky.
Thanks Dan. There is ways to make quick work of it though. Once the old cut out was filled in and smoothed, it is a snap.
Headlight lens form is just some laminations laid up over fender to copy it. Since it is formed to the outer shape, it will transfer the shape to the outside of the plastic lens, so it should fit perfect and correct "bubble".
Then mark on fender your headlight lens outer dimensions. Then mark inside of that your flange width, I did an inch. Cut out the mark inside of the flange first, and drop the center section. Then cut out the flange to leave only the lens outside line. Because of the curve on the side, and the fact the flange will mount inside, it is just a touch smaller when mounted underneath and can be bonded in to make your flange. Little bit of bondo to smooth and radius the transition, and boom, done. Only a couple hours into what you see done, starting with a full fender and not cuts.
I usually spend a bit of time planning the mold/mock up process to make it as quick and effecient as possible. In all honesty, I hate fiberglass work! :laugh: Cool when it is done, but itchy as hell, messy as hell, dusty as hell, and I always seem to forget a mask.........for years now. Haha.