Headlight bucket fit

[DavidL]

I'm working on getting the headlight buckets on a 1967 Mustang to fit nice and tight to the fenders. The drivers side fit really well but the passenger side has a good size gap between the fender and the head bucket on the outside edge. What is the best way to close this gap? My initial thought was try to squeeze some filler in the gap, let it cure then remove the headlight bucket but want to get some options on what might be the best approach.

 

[Senile Old Fart]

What is holding it out?
That is where I would focus my efforts.
Is it tight fitting in some spots and not all the way around?
If that is the problem verify the head light bucket is true, then massage the spots of the fender that touch the bucket back a little bit so the wide spots get narrower.
It could be the part of the fender that the bucket mounts to needs to be tapped back a bit until the bezel fits right.
Could take a bit of both approaches to get it right.
I would not fill it with bondo, just something to crack and fail later on imho.

looked at your pics in large view and can see where the bucket is hitting the at the bright spot, appears as if the fender is pulled forward at that point.
other item is the side gap, very wide at the bottom, that sure looks like the mounting area on the fender for the bucket needs to be massaged back a bit.

OR you can wait for one of the Big Dogs to speak up!

 

[DavidL]

Thanks SOF, I worked on this again this morning and figured out the problem. One stud on the head light bucket was getting hung up in the mounting hole and I was able to push everything back into alignment and it popped right in and looks much better.