Greg, do you have a "flanging tool"? This is a press-type tool that makes a little jog in the edge of a piece of sheet metal. By doing this to both the fender and the added-on flair, the pieces lay perfectly flat for spot-welding or even seam-welding, and only a skin-coat of filler is required. Eastwood sells a flanger based on vice-grip pliers that works well if a little slow. And its cheap!
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