I'm still picking rust out of my nose.

[spacemanspiff]

Welding! Sounds fun! What do you do about the seams? Bang them in then bodo?

Pretty much. With a little practice you can make a really nice weld with a mig welder. I got a small one from Home Depot that works with or without the shielding gas. Just make the weld, grind it smooth, tap down the high spots and lay on a thin coat of bonbo.

To cut the pieces, I usually lay the new piece over the old one, line it up and clamp it in place, then cut both at once with a cut-off wheel on a die grinder. That way the edges match.