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Use foil. It's what guys use when making custom sub boxes and it works great. Keeps things from getting on the surface you're trying to protect and won't dissolve from the epoxy. The part touching the headlight doesn't need to be super smooth because it won't be seen, just the exterior. Other thing you might consider is how thick you want the part to be. You may need several layers. I actually have a spare headlight I could experiment with if I was motivated enough to do so. lol
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