Any fibre glass guru's out there?

[RazMan]

My kit car's front section is really designed to take recessed lights with a polycarbonate cover - but I want to be awkward and mount BMW Mini headlights in the larger square holes. I will need to make an infill panel between the headlamps and the existing body.

Where do I start?

I have spent the best part of today scratching my head about this - and I think I have a plan....which saves me having to make moulds (coz I'm lazy )

I intend to mount the headlights in position with ally brackets fixed to the inside of the wing. Then, working from the inside, I lay fibreglass matting across the 'void' between headlamp and existing body. This will form a rough shape to apply filler (on the outside) and fine tune it until I am happy. I can then remove the headlamps and tidy up the inside.

A couple of questions to any fibre glass guru's out there.

1. Will the bond between the matting and existing body be strong enough?
2. Is the filler liable to crack if I try and keep it to a max thickness of say 10mm?
3. Is there something I can use as a non-stick surface to prevent the resin sticking to the headlamps? Mould release compound maybe? Vaseline?

Am I close to a masterplan or complete cock up?

[RazMan]

Thanks for your input Steve

The light unit is a really neat design. It contains all the beam adjusters (left/right & up/down) so I just need to get the mounting roughly right and then fine tune the adjustment.

The bubble wrap idea is inspired - it will allow me to extract the light unit even if the resin really grips on hard and prevent any mess once everything is removed

[RazMan]

Thanks for the ideas guys - The packing tape dodge would seem to be the easiest way as I have loads of it available to me

I'll be having a go at this in a couple of weeks when I take some holiday. I'll let you know how I get on.