Well I had some fun on the weekend, went to fit up the headlight buckets onlt to find that like most Zeds there was uneven gaps between the fender and the cone...so I came up with an idea that worked fantastic. I thought I would post some pics in case anyone else encountered the same problem.
What I did first was to make a template out of thick card that would protrude about 2cm around the guard and bucket, I then bolted it together and applied body filler up to the card on both sides. When this had hardened well I then did a rough sand to remove most of the excess filler. I then removed the bucket from the fender, removed the card (carefully) and then reattached the bucket. Then using a hand flat sander made sure that I sanded accross the fender and bucket to make sure they were even. Separate the bucket again and sand a small chanfer (beveled edge connecting two surfaces) on the bucket and guard. Prime both surfaces and reattach...and presto perfect gaps with factory appearance.
