[Travis K]

I didn't flange it, I prefer butt welds. Besides, it would be tough to reach seam sealer all the way around and make sure it is covering the seam well. I wonder how welding in an oval hole creates less warpage than a square hole? I may try it when I fill the side markers. The way I see it, heat is heat, and that is what warps the panel.

Even if you don't have any bed cutoff for the flange, it wouldn't take much to form a 1" strip to follow the contour. I think it would have taken less time to do that than cutting off the piece and removing all of the paint and undercoating. Plus, it is satisfying to make something like that from scratch.