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Good point, lol. And yeah, I mean weld upside down and yeah, it does get uncomfortable. Especially the nice sizzling balls of molten metal that bounce into your ear and make a bunch of noise for a few seconds. I have always wondered why that doesn't hurt like hell but I guess I should be glad...

No idea on the holes since that's not my area of expertise but as far as the crack, I'd weld it, grind it and then put it back together with a decently large plate behind it. Something that spreads the load out about 2" in every direction and then I'd tack weld the plate to the cowl so it will...