I need to do some long runs on 2mm aluminium sheet. Planning to use pulse mig, Normally I would set it up inside corner to inside corner so I have 2x 2mm faces to weld against. In this case I would like some location tabs/slots cut into the sheets which rules out corner to corner setup. So I have a few options, Recess the slots for the tabs by 1mm so I am left with a 1mm face to weld against a 2mm face (red=weld bead) Recess the slots by 2mm and run along the face Or cut holes for the tabs so they slot through and leave a overhang for a fillet. Option 1 looks like the best bet to me although the sheets are over a meter long and trying to hold them within 1mm over that distance might be a challenge but I am thinking I can put tacks on all the tabs then weld the joint runs up. Option 3 might be the easiest way to hold everything in place but i am concerned i will end up with a distorted edge on the stick out unless i clamp a backing bar to that as well somehow. Any tips?