The method of "cut and butt" described in good detail by Bartamos really works well. If you are interested in seeing detailed videos of this method, do a web search for "Fitzee's Fabrications"on Youtube. Tony Fitzee, located in Newfoundland, is a wizard at this method. I have watched all of his videos, and after seeing them, I changed my method of welding patch panels to fit his advice. Since that time, I've welded in many replacement panels, including an entire top cowl, patches in fenders and doors, side cowls, and quarter panels--the results have skyrocketed in both ease and quality compared to my previous work. Take a look at Tony's videos--they are not only edifying, but plenty entertaining--and you will learn a ton about doing metal repair with very few specialized tools.
