The headlight bucket base should be essentially flush with the fender opening when up. If your buckets are both flush when down and resting on the rubber stops but off by an inch from one another when up, then the bucket itself is either bent or your one fender is misshaped somehow. It is also possible that the buckets themselves changed in dimension over time and your one bucket different in size from the other. Did you measure the actual dimensions of both buckets?
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