I had the same problem with mounting mine on my R6. I think that it is impossible to get the gap out unless you bend the back plate. On the R6messagenet there were some instructions on how to mount flushmounts which explained that you had to slightly bend the back plate to get them to follow the contour. I couldn't bend them so mine have a little gap to. It's really small and unnoticable though. I just wonder about moisture getting in there?
Here are those instructions:
To mount the LP Type I Flushmounts without drilling:
- I fabricated a backing plate using thin sheet metal, similar to the flushmounts' base plates. This plate will go inside the fairing to make a sandwich effect with the flushmount on the outside and the fairing in between. Make sure your hole in the inside plate lines up.
- Drill a single hole in the flushmount's base plate, right in front of the light bulb socket. Basically, in the middle of the flushmount. This is where the mounting screw will pass through to the other side. Use a flathead screw to avoid conflict with the bulb - about 1-3/4" long. Not very fat - like 1/8" or 3/16" is plenty.
- Drill another small hole, a little below center and just in front of the spot weld for the socket bracket. You'll need to pass the wiring through this one.
- Gently roll the flushmount base plate over something round like some PVC pipe or your mother's rolling pin. You want to get just a "slight" curve to the plate so it will contour nicely with the bodywork.
- Time to make a sandwich! Put it all together now. I used a nylock nut on the inside along with a fender washer. That allows me to crank it down tight so the signal doesn't slip and the nylock nut will prevent it from vibrating loose. I might tend to over-engineer things when it comes to fastener, but I just can't resist all the little buggers when I'm rummaging through the drawers in the fastener aisle at Lowe's.
- If you did it right, the center screw that hold the sandwich together will just poke through the hole that's in the black inner fairing trim panel.
- Put the bulb in, and treat it just like a car headlight - alcohol and no touching with your fingers.
- Install the lens housing and be sure not to crank the screws down to hard. You CAN crack the light housing if you do that
