Swifty, Mac, Mr T & Oxford - Thanks for the replies chaps.
Those "straight edge" jokes really did make me laugh.
But they also reminded me that all old Sammio builders have alignment "issues".
So I will simply get everything as straight (ish) as I can and make the "join".
By the time the body shell and cockpit panels are in, it should all be very solid.
OK, it might be solid and a bit wonky too.
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Ticking Over
Whilst I haven't had much time on the car, I have still managed to get a small job done.
Before I started welding the first "join" bracket, I practised on some "off cuts".
( As the plate is significantly thicker than the box section. )
Once I was happy with the welder settings, I switched to the real thing.
I do find it much easier to weld thick metal compared to thin.
Next it was a straight forward job to "cap" the end of the box section.
I'm really pleased with how solid this bracket is.
Which gives me hope that by using 4 "joins" I will be left with a secure structure.
Until next time, take care, Paul.