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My biggest recommendation is to invest in a tin of cyanoacrylate (superglue) activator. Dab of superglue on one side of join, spray of activator on other. Bring together and ZAPOWEEEE - instant join! Takes the pain out of metal assembly right away!
Of course it doesn't eliminate the problem of the requirement of pinning for strength (and to be honest, any joints that take any strain should be glued with 2 part apoxy resin adhesive/Araldite as well, as it is stronger than superglue and more robust), and gaps will still need to be filled. BUT doing both those things is sooooooo much easier when it is all held in place by set superglue! Believe me!
Of course gaps are an acknowledged problem with large metal models (PP Khador 'jacks are infamous for the "Khador Gap"!), and it is something that you have to live with. However clagging in a lump of greenstuff, smoothing it off and leaving it overnight to dry is hardly a strenuous exercise, and then once it is complete you have the benefit of a finely detailed and crisply modelled final product - free of the usual banal blandness associated with the plastic alternative!
And if all else fails, you can wrap it in a sock and use it to fight off burglars.
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