Well, I've opened up a small can of worms.
Ya know that lip metal that sticks out from and transverses the entire firewall? The one you always catch your hand on and cuss? That's a body seam, and I decided after a couple of barley pops last night it needed to go. So without completely thinking it through, I cut it off flush with the fire wall. Oops. Turns out that's an intersection of 3 separate pieces of metal, all spot welded together.
So I sat there pondering what to do. I tried welding it back together, but I can't reach everywhere I need to, plus the metal was ground too thin *cough cough oops again*. My next hair brained idea is to go to Home Depot and buy some 1" thin wall tubing, cut it in half long ways and weld it over the seam, heating and bending it as I go to match the contour.
If I can do it correctly, I think it'll look sharp and you'd never notice I did anything. Or it'll be another "I think I'm going to hack the front end of my car off" idea. We shall see...
On a lighter note, the guy that sold me the intercooler is selling me a BOV for $40, and he's going to TIG weld the flange to an aluminum 90° elbow and ship it all to me. Is that a cool guy or what?!?