7h. Frenched Headlights

First the basic cut out is made and drum sanded with a high speed Dremel tool.  A template is then created to match the hole on both sides.

Next tapered tubular preforms (cloth, mat, cloth) are fiber glassed over the actual halogen lights (protected with masking tape).

After curing the headlights are removed and the slightly tapered tubes are ready to be glassed in place.

Skinny strips of cloth and mat are resined to the tubes on both the inside and outside seams.

After the resin has cured, the tube extension is trimmed flush with the hand guard surface.  Here is the final effect of the "Frenched" or scalloped  headlight.