fitment is as important as the weld (or more so). If the pieces dont fit well in the first place, then you will be blowing through the gaps and 'chasing' the holes...making things worse. Good tight fitting pieces are easy, as your new test-piece shows.
Grind them down, try to lightly fill the holes/gaps, then once its all filled in go over the joint making a nice fillet. Repositioning the frame/bike to the easiest (horizontal) position for each weld might be a pain in the butt, but it will be worth it. Much better to take your time than to have something break and potentially get a mouthful of asphalt!:thumbdown:
ut:
edit: CLEAN METAL WELDS BEST!! Clean all the paint/slag off the area to be welded!!
Thats what I would do............but thats just my opinion.:wink: