Projects '59 Ford Custom 300 Trunk Pan Ideas

You can do it! I replaced big chunks of my '54s floorpan with patch pieces. All you need is a cheap HF bead roller, HF brake, MIG welder and some patience. EMS is good but pricey. I went to my local metal supply shop and bought $80 worth of 18ga remnants and still had a whole bunch leftover. You can check my build thread for some inspiration.
https://www.hotrodders.com/threads/1954-ford-customline-build-thread.545181/#post-4808136

 

Agree i do lap joints where i can but use a flange / joggling tool + hole punch and spot weld this gives a flush finish and helps prevent panel warping , ideal for fender / door skin and quarter panel repairs

 

When it comes to making flanges I have one that goes on my Air Chisel. I modified one side of the top die and can just start on one end and slide while hammering to the other end of a panel. Works well.