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Re: Cab corners
Yes to your last question. In fact, it might be easier to use a lap weld, rather than a butt, with that flux welder. If you could find a way to create the lap joint. My HF hole punch does a pretty damn good job.
Use the part you cut off as your pattern on the new metal. If your going to do the lap, measure 3/4" more than that. Masking tape will make this gap for you easily.
Lately I've been sheet-metal screwing new metal to old and cutting both at the same time.
You could definitely put a little strip of metal behind there too. That's basically how they do adhesive patches.
If you do that (and maybe if you don't) you might consider some weld through primer on the metal that the welds will trap from paint.
You can use magnets to hold everything, but don't weld directly one them. Heat causes them to lose magnetism.
You can hold copper to the back side of your weld to prevent burn through...and you can't weld to it. Smashed copper pipe will work, but you can melt it.
I welded the first half of my cab with a flux core. It can be done.
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