After freaking out a bit (because it took me over a month to find a new fender last time and it was a 7 hour drive each way to get it), I decided that I should take the same approach as I've taken each step of this project.
How do you eat an elephant? One bite at a time. We're going to do this in pieces and hope the fender doesn't fold in half at the corner.
This bit first.
Turns out the seam section that I cut was held by two pinch welds. I was able to separate the two layers of the fender with a putty knife and then grind down the two bits of pinch weld.
Make a patch.
But, I don't like that porous metal on the second layer, so hold off on welding the patch in.
Cut out the ugly metal, create a patch and weld it back in. Holes are for plug welds to the previous patch.
