Got quarter repair patch ready to weld in. Going to put pix in order. Gap is approx .030" all the way around to allow for penetration and expansion. Using spray on machinest dye i scribed where i needed to cut and file using the patch and a circle template as the templates, Part is taped from underneath with aluminum tape. Will be using high strength magnets to hold it as i tack it in. I prefer rounded corners. I am in aviation sheetmetal repair for a living. In my line of work, sharp inside corners are stress risers for cracks. These probably would be ok welded up in a car using square corners, but old habits die hard, or are hard to change lol.