Headlight bucket fitment

[Kris 90]

I’m having a problem getting my passenger side headlight buck to line up. The drivers side went on with no issues. They are both OEM as are the fenders. When I get the top lined up the bottom is 1/4” off to the fender as you can see in the picture. I don’t want to put that much filler on there. The only thing I can come up with is to cut the spot welds on the lower fender and push it in then reweld it. Wanting to see if you guys have any ideas. 

[Brian Conway 264]

Is the lower attachment at the valance holding it out ?  Just a guess but I would look around some more before any cut and weld.  Brian

[Kris 90]

No I haven’t installed the front valance yet.

[RPM 1,190]

Once I had the fender, fender extension and valance in place and ready for final alignment and tightening, I couldn't get all three aligned perfectly. I had to get then to where any one area was not too obvious of misalignment and called it good. These car panels were not aligned very good when new. 

[Ridge Runner 1,112]

The fender is spread out at the front ,pull the bucket and very carefully push on the tip of the fender and the lower side at the same time ,be gentle it bends very easily  

[Ridge Runner 1,112]

You want it to bend in from the middle ,i see this a lot on 67 68s 

[mustangstofear 608]

We bust spot welds all the time to get a perfect fit.  

[Kris 90]

Ok thanks. I can push it back into place but as soon as I tighten the nut it pulls over. I’m going to try to bend it first and see if that will work. 

[Ridge Runner 1,112]

Put a washer under the nut ,make sure the pot metal part of the stud will not fit through it 

[Kris 90]

I had tried the washer already. I looked at my other fender and I saw where it didn’t have any gap between the inner bucket and the fender at the bottom. The fender that didn’t fit has an 1/8” gap. I drilled out the spot welds and moved it to match the other one and now it lines up perfect. Thanks for all the suggestions.