thats *alot* of welding ;-P
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well if it saves spending heaps and having to keep changing the arena floor all the time
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I was thinking about just small patches around 30cm square or less. If we thinned the edges and just stuck them down with building adhesive, it wouldn't be too much work.

just putty up the holes would probably be enough in that sense, and you don't then have another edge to get stuck on, doesn't help too much with the edges lifting up problem though.
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i dont think the mdf floor would be too bad to be honest. maybe if we use little tiles we can make a heaps of spares and just throw new ones on when there totally unusable.

i guess with a good circ saw and a jig we could get plenty of squares out of the way

We would cut all the MDF tiles on a table saw like mine or Chris's - very fast and accurate! Tiles around 30cm square would be about right - how would we unstick them from the floor when they get damaged?

Crowbar?
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not sure how youd mount them to the floor (maybe just a press fit almost?) but you could screw some screws into the wood and yank it out that way i guess if its ruined

30cm seems pretty small... i'm sure we can fit in the small 3mm MDF sheets you get and slice the edge ones to fit?
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i think the idea with small ones is you can just make heaps of them and replace them as needed. so you dont need to go and replace a giant 1.2x2.4 sheet everytime scissorhands digs a trench out of it

A lot of the holes put in MDF you can just fill in with car bog. It's cheap and can be done between rounds, might save you turfing so many panels out.
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Every tile would mean 4 more lips to lift up.
Full sheets are the only option,But the persons who trash the arena needs to clean and fix it between battles and if needed between events
I can buy 2400x1200 16mm mdf at $20 each and cut then for $0 the cost isnt the issue its the maintaining that needs to addressed.
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I honestly don't think 16mm is needed, 6mm or around would be plenty, and 1/3 of the cost. I agree with that idea too, if you rip it up, you fix it.
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Thinner MDF is too flexible; the edges would lift up really easily. 16mm will support its own weight and the extra weight will help to hold the sheets in place.