Ready to weld, but helmet battery died

I would of had the new patch welded in were it not for the battery in my helmet being dead. What a surprise when I struck a bead and the glass did not dim. My eyes hurt for hours.

I decided to open up and smooth out the opening a bit, one cut on each side. ( Compare with this .) When the shape was finalized I drilled holes to weld through. Two were where the electric drill could not reach, on and just below the grill mounting tab, but I was able to use a right-angled die grinder and a tapered file. Took a while, but turned out rather well.

I washed everything with POR-15 Marine Clean and ran a wire brush in the die grinder along the edges and over the holes to remove all the paint. Painted the inside of the patch with weld-thru primer.

I left the patch clamped in place so next time I can start with welding in on.