Excellent post! Thanks for all the photos and details. It turned out great.

 

My 02 1500 had fender flares and they lasted until the day I sold it (2 years ago). I personally love the look of fender flares especially if you have wide off road tired. Good job on the repair! I did the weld in metal panels, as I'm a welder and painter, when I first got the truck and they lasted even to this day (do did the flares a buddy bought my truck). I believe what happens is salt, mud, and road grime sit up there between the plastic fender liner and the metal which cause rust.

 

When rust eventually happens with my truck, I'll end up going the flare route, but like OP, I prefer the lines and subtle curves of the vehicle the way it came from the factory.

 

My options were
1. Buy $50 fake bolt on fender flares (like the OP)
2. $3500 for wider fiberglass fenders and bedsides