I like to use the flanger whenever possible but it won't work well on curved surfaces. I try to place the offset about 1/16" from the other edge to leave a small channel to weld into. That way there's less weld material to grind off. If it's a curved surface and the back side won't be visible, I sometimes cut a narrow band of sheet steel to back up the seam and prevent blow-through. Otherwise, it sounds like you're already doing everything I know to do. You'll only have to use enough bondo to smooth everything up so you shouldn't have any problems.
Last edited by jfnar; 01/06/2011 11:32 PM.
