Now is where I really went round and round... I knew there was no whay I could re use or would want to re use the stock tailight. So I searched for some time for a light that I liked. I wanted a stock light from a stock bike. I want my bike to look totally custom but almost stock at the same time (im thinking less hassle from the 5-0 the better) SO If I got a stock light from anotehr bike then the light is techincally "DOT Approved"
the light I found that I liked the most was off a 2008 honda VTX 1800.
Thank you E-bay I picked one up for $50.
There really was no good way to test fit without cutting since about 1/3 of the tailight is designed to be recessed. so I busted out the saw and went to town on the fender.
I used bondo to fill in all the old mounting holes from the old lights. You can also see my seat brackets in these pics.
Here is the first actual "test fit" of the taillight transplant
You can also see I started sanding the tins.
The problem I ran into with the taillight is that the fender for a VTX is really very flat and has very little curve to it at all. So in order to get it to fit the contours of the Vulcan fender I used a belt sander to grind up the edges of the light right in the middle and basically ground the curve I needed into the taillight housing to fit the fender.
This was good but not good enough, I still had about a 1/8 - 1/4" gap between the fender and the rear most point of the taillight. I ended up using bondo to build up and form the fender into the shape of the light at the back. I feel it came out pretty good and got rid of the gap.