I am patching the rear corner of the outer rocker. From the flange that welds to the inner to the first of the three folds. I have the patch cut about 2 inches larger then the rocker and I planned on butt welding.

My question is what is the best way to cut the patch so the seams are nice and straight.

One thought is to overlap them clamp them then cut through both. The other option is to go very slow with the grinder removing a bit @ a time and trial fitting.

:beers:

Make up a template out of white card board to fit the hole.

ive done both ways make a carboard template and transfer or cut thru both pieces with a thin bladed cut off wheel 1/32 or so. just depends on how much room there is where you are working
good luck scott