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Video: Build a Fireplace, Brick by BrickHighlights
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I'd vote for soldered copper, but there are many methods, including solvent welded plastic sheet that may work just as well. I try to avoid custom pans.
*Here's a link to a JLC article that may be of some help.No personal expertise, so the best I can do is give a reference.
*As far as curbs go I steer away from timber and always use brick. These can be cut and glued in place with Maxbond or similar.Now your waterproofing. This is a major cause of rectification problems down here so it is now mandatory to seal with a product called Wetseal or similar. Basically this is a fiberglass or acrylic resin over reinforcing mat ( fibreglass ) that is applied over the whole pan area and down into the waste pipe ( before the waste is fitted ) and up the corners of your backer board and any joints in your backerboard.No-one renders on walls here. We use Villaboard a James Hardie product right through the wetareas. It has a recessed edge just like drywall and is set the same. We tile straight onto it.
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