Hi Tech Gap Filler

[brianrupnow]

This is a quest for an educated second opinion. As you can see in the picture, the ends of my new stainless headlight bar is not a very good match for the curvature of the fenders. (same at both ends). I do not want to start tying to bend a polished stainless headlight bar, and I REALLY don't want to mess up the paint on the fenders. If these were metal fenders, I would just snug the bolts up untill everything "conformed", but thats not wise to do with fiberglass. My initial thoughts had been to make a tapered metal shim, but after thinking about it, I think this would be a good spot for some high build epoxy filler. If I can cover the fender with a layer of aluminum foil (plastic sheeting won't work, I had a horror story with that 2 years ago), trowel on some high build epoxy,---something like J B Weld. coat the headlight bar with a heavy layer of paste wax, and then bolt everything up "snug"---. My theory is that the high build epoxy will conform exactly to the gap. Then, after it hardens, I unbolt the headlight bar, and trim the squeezed out epoxy to be an exact match for the end of the headlight bar, and paint it either silver to match the headlight bar or black to look like a "gasket". Opinions please---Spring is coming, and I want to be ready.---Brian