In the end after half an hours messing around with masking tape, I gave in. Looking at the top, the overlap was huge so maybe the bottom didn't need to be either hugely accurate or particularly neat. Looking at the two with the aid of a nice big mug of tea, it seemed that if the top was parallel to a bulge that runs around the hull (there will be a technical term to describe it but I don't know what it is) then that should work OK.
The only pen I could find that would work on the surface plastic film was a chisel tip permanent marker. A bit of digging around on the bench turned up a screwdriver, which when taped to the pen gave me a suitable separation. The line around the hull was wobbly but with some scissors I managed to cut along it reasonable straight.
So I took the two parts into the garage, turned the unit on it's back and filled the gap with shower sealant left over from some DIY. This should remain flexible forever and keep the water out. It's a bit like icing a cake with something smelly but the join seems good and strong.
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