Manx Club

Jerry I saw the picture of how you improved the headlight mounting cup in the dashboard thread. Great idea! Filling the cup with fiberglass gives the cup a bigger and more secure footprint. You talked about cutting a contour into the bottom of the glass after it hardened. I think you could just tape some polyethylene plastic (garbage bag) over the little bump the headlight mounts on and then just put the cup filled with bondo hair (bondo mixed with chopped strands) on top of the bump. When it hardened it would have the perfect contour. The bondo won't stick to the garbage bag. I kind of did the same thing when I re-used an old Manx dash frame. I ground a saddle about 1/3 of the way into the cross bar for the column to fit into. Then I filled the hole up with bondo hair. I wrapped some garbage bag around the column and pressed it into the bondo in the crossbar. When the bondo hair hardened it made a perfect saddle for the column to be held in by the clamp. Whenever I fill a hole in fiberglass with bondo hair, I always use garbage bag to cover the piece of wood or whatever that I use as a backing. When it cures, the garbage bag pulls away and leaves a super smooth surface.

The bag is a good idea. I used waxed paper to keep the fiberglass from sticking to the clamps when I glassed in my hood and it worked real well too. On my Siggy Manx, I turned the body upside down and filled the headlight mounting posts, about 1" with fiberglass resin and roving. This made a nice flat area for the washers and nut to tighten up against.