Geez, after all that screwing around you could butt weld 4 patches... and get a much better job in the bargain.
Here's how I do it:
~ Overlap your patch to the original part by about a half-inch.
~ Sheetmetal screw (#8) the two parts together.
PICTURE ~ Scribe a line along the edge where the parts overlap.
~ Remove the patch and cut along the scribe line leaving little tabs where the screws go.
PICTURE ~ Screw the patch back on.
~ Tack weld to hold the parts in place.
~ Remove the screws, cut off the tabs and finish welding using a hammer and dolly to maintain alignment.
PICTURE Do it right and you'll have something to be proud of when you're finished.
