REPLY
Someone asked me about fabrication of a headlight bucket? I can't find your post, but i'll try to help. I made one to replace a crappy rectangle headlight on a Tomos scooter once, and here's how.
I wanted a round one, so I actually used a ballon for the shape. Since the polyester resin would eat through the ballon and pop it before the gelcoat hardened, I spraved PVA (Poly Vynl Acetate) on the ballon as a relese agent. This worked better than wax because it assured me a good thick coat and was quick. I then applied my gelcoat and a layer of fiberglass mat. after lightly scuffing up the glass, I then built it up with heavier glass. If u don't do this u will get print-through of the pattern of the glass due to heat from the curing process.
I deflated the ballon and took it out, and cut the mold down it,s center. Keep in mind the front of the bucket was unnecessary, so i didn't make an entire sphere. O.K., I cut it so I could remove the part from inside of it w/out damaging it later. Be carefull cutting to not chip off gelcoat from it's edge.
The 2 halves i placed on a waxed peice of plate glass, and laid down gelcoat and sucessive layers of glass to form a lip that would mate to the other side. Pull both pieces off the table and put yhen together lip-to-lip and align them. clamp the flanges together when they're flush inside, and drill some holes through the flanges to put bolts through. with bolts in place and both halves waxed, here's your mold
To mahe headlight mounts, make them in the finished part as tabs glassed in from the inside. a nice peice of shiny cardboard waxed up cut into a ring for acess put against the lamp opening will work great. Hot glue will temporarily keep ot there for you and peel off of your gel w/out damagong it.