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I'm not a big fan of 100% argon for mig welding. Argon is primarily used for tig and is only recommended for mig when doing sheet metal. I think you'd be better of using a mixed gas ... C02/argon and if you do anything other than sheet metal it'll perform way better.

Lap welds are never pretty but suit yourself. Cut the new panel about 3/4" bigger all around. Finish the edges micely - both the whole and the new panel. Sheet metal screw it in place - about every 2". Now run a short bead on the edges in the middle of all the screws. Take the screws out and weld up the holes. All the screws prevent warpage. I wouldn't bother welding the whole perimeter - I'd just seam-seal it and paint.


The screws are a good Idea and stitching at there placement,a box of 50 would be just right.

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