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David, I found the belly pan as some of the more difficult work on my restoration because of the angles and curve of the metal. But it is a bellypan so perfection is not needed. Mine is a 1950's trailer so the degree of difficulty may not be the same. Not sure how to answer your first question. You could simply rivet the overlap of the sheets together. It does not need to be sealed/ watertight and in fact needs to not be water tight so it can drain. Expect that some water will get into your bellypan and needs to drain. Having said that I would work to seal the water entry site you mention at your bumper. No point in allowing water to enter if preventable. I used a combination of polyisocyanate insulation covered with reflectix. It came out very clean and neat. I did install aluminum vents at low points in the belly mostly in the front and rear. These were round 4" small louvered vents I got from Ace. I added screen to the inside to keep out critters. I thought this was a good way to assure drainage and ventilation. Ed
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