Then the problems started when I tried to fit the cowl.
I can only assume that the internal headlight piece that connects to the frame isn't correctly located within the cowl. There's nothing else for it, it's going to have to come apart. I've ordered some debonder from Amazon, not sure what effect this will have on the paint so might end up having to strip it all and start again.
I managed to get it apart with minimal damage and have stripped the paint off the cowl and light clusters. Just priming now and will get the top coat on later.