Almost done with the first one!!
OK, after a decent amount of work today, I am pretty much almost done with my first headlight. Just have a few minor things such as drilling a hole to run the halo wires through, resealing the clear cover and housing and then putting the 2 back together. What I accomplished since last night after I plastic welded the housings together and the bezel/middle housing (???):
I used bondo for the first time in my life to fill the gaps around the head housing combo. It was an interesting experience, and as you can see from the pictures, I didn't sand it down all that well because I don't really care for right now. Its inside the engine compartment so I'll be fine for now. I also used bondo to create a more solid look of the bezel/middle housing. This I spent more time sanding it to create a smooth appearance, but the lack of sand paper choices I had prevented me from getting the perfect look. This will be corrected for the next headlight. Finally, I painted the bezel/middle housing with a high glass black Krylon Fusion paint, re-mounted the halos and put everything together for a final test fit and a couple pictures to see how it all looked. And my I have totally impressed myself. I hope you guys like how it looks!
Pre-sanding 1st bondo ever
http://pic1.picturetrail.com/VOL1172.../321221444.jpg
Post-sanded head housings
http://pic1.picturetrail.com/VOL1172.../321221449.jpg
Bondoed and sanded bezel/middle housing
http://pic1.picturetrail.com/VOL1172.../321221450.jpg
Painted bezel/middle housing and halos attached
http://pic1.picturetrail.com/VOL1172.../321221439.jpg
Test fit w/o clear cover
http://pic1.picturetrail.com/VOL1172.../321221440.jpg
Test fit w/clear cover
http://pic1.picturetrail.com/VOL1172.../321221437.jpg