Abstract: A welded lap joint is made in sheet metal panels by folding over the margin of one panel to form a U-shaped section and to crimp within the U-section a sheet metal spacer strip thereby producing a three layer configuration. The margin of a second panel is formed into an offset by an amount equal to the thickness of the three layers of the U-shaped section of the first panel. The offset margin of the second panel is spot welded to the bent over margin of the first panel using a conventional welding electrode bearing against the margin of the second panel and an electrode of large load distributing area contacting the top surface of the first panel so that the weld nugget formed between the margins of the two panels is isolated by the spacer from the surface of the first panel to avoid weld marking of the surface. The resultant product comprises first and second panels in the same plane and separated by a very small crevice. The crevice, if desired, may be filled with a filler material such as a plastisol.