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My experience is to go just a bit beyond the visible end of the crack, seems it's often cracked, but not visibly opened up, got to literally "get ahead of it"
I would think the hardest part would be to find a welder to do it. I had a hairline crack several years ago and called up a couple of welders in the area. They told me, sure, bring it in! I'm like, I can't exactly bear hug an 800lb stove and throw it in the back of my Prius!
I had a crack right around the door-frame (nothing to do with the discussion of this thread) and a mobile guy came (with his young daughter as helper) and fixed it for $50, which BK cheerfully re-imbursed.
Nice. Not gonna happen around here. Bring it in, or at least drag it out into the yard ("if I do it in your house I'll burn your house down!"), and I think the quote if I did that was $200.00 to come out. Don't think anyone would be reimbursing that on a twenty year old stove. It's hairline and the cement works good. I just sand it and renew it every year to insure I have good coverage. I originally tried JB Weld high temperature, but it crumbled off first fire!