I wanted to run my rust plan by you all as well as post some pictures to see if anyone had specific concerns/thoughts on any of the areas.
Purchased supplies yesterday and plan on making this a weekend project, I'm in no hurry and should point out that I bought the car in the NE and drove it back to Alabama were we don't typically have to worry about rust. My plan is more focused on the immediate treatment of the existing rust than long term prevention/annual treatment etc.

Plan:

Wire Wheel all existing rust
-purchased a wire wheel and a knotted cup brush
Clean brushed surface with POR degreaser
Use POR metal prep

I bought 2 types of rust converter, so I'd love to hear thoughts on use on or the other or I may try some spots with each type to look at the results
-POR-15
- Permatex



Pictures attached, any thoughts suggestions would be appreciated.

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Sounds like a plan. For inside the frame I'd use something like fluid film.

For the face of the differential housing pumpkin (where the fill plug is and the brackets for the brake cable), that metal rusts differently than all the rest. It "sticks" there rather than flaking off and can be quite a bit deeper than it looks so the POR15 might not perform well there. I'd get out a dremel and grind off all the nooks and crannies until you get to all sound metal. You won't believe the amount of red dust that comes off.

Mine includes plugging the holes in the frame with rubber plugs and a heavy dose of fluid film.

I've used a Permatex product in the past that was kind of milky -- don't know if it's the same as what you've purchased.

If it is, it's essentially the same as POR-15 Metal prep. I believe it creates a zinc coating.

The POR-15 encapsulator (paint) is what sets it apart from other products. At least that's been my experience.

got it, I was thinking they were both a rust converter, sounds like you could use the POR after using the permatex

Thanks for the suggestions gents, I'm excited to get this project going

Need to fix your exhaust before you die. Route it out from under the truck.

My plan was:
Wire wheel
Corroseal Rust converter
Rustoleum Rust converting primer
Eastwood Chassis paint

Seems to be working well so far

In your last picture, just above the exhaust and to the right, is that a crack in your frame or just cracking rust flakes?

I think I'd have a really thorough look at your frame if it is a crack, might be more work than initially looks. Hopefully not though.

So I only glanced at your post OP. From expierence this is what I can recommend.

Wire wheel the crap out of ANYTHING YOU CAN REACH. And you should be able to reach a lot of areas. Please wear good SAFETY GLASSES.

So this is how I fixed my rust.

Wire wheeled
Degreased it with brake cleaner.
Primer or rust convert or. Although I think rust converters are just BS.
Then VHT chassis paint.
Por15 rocker panels and under body.

For inside frame. Power wash it.
Eastwood interframe coating
Fluid film or Eastwood heavy duty grease for inside frame and outside frame.

I'm not a fan of rust encapsulate products (POR15), that needs rust to aid in adhesion.

If the job is to small or inconvient to sand blast the rust, down to bare metal:
I use wire wheels &/or a $20 deburing tool (aka small end mill type) on a DeWalt drill.

Next coat de-rusted metal, with Permatex Extend / converts rust to a phos. coating. https://www.amazon.com/Loctite-8-Oun...K3KAG9P4MX8BTS
Epoxy prime is best, to seal out moisture, followed by a enamel-oil base metal paint. www.southernpolyurethanes.com/
- below trailer hitch, was severely rusted / the 3/8" diameter deburring end mil, worked great
Finally - spray undercarriage with Fluid Film wax-oil.

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Safety is a must with those wire wheels. The metal wires will fling off and embed themselves into your skin. You wont feel them until you try to move and realize there are 20 little metal spikes embedded through your shirt and into your stomach. Otherwise they are very effective.

I would Wire wheel all the heavy rust off and put the POR-15 over it. Multiple light coats and it will hold up for a very long time.

Cant help you on the Inside of the frame since I have never done that.

thanks for all the replies, I'll probably get started with the wire wheeling this afternoon. I plan on taking detailed pictures as I go

Thanks for looking out, I crawled under last night and verified it's just s rust flake. Not a cracked frame

just an update on the progress, spent a couple of hours on Sunday with a wire wheel and mad some great progress. As noted above the "pumpkin" has some crevasses that are better with a smaller tool. About 75% of my way through the day I unfortunately found some frame rot that I missed when I was purchasing the car. Will be assessing the frame in its entirety when I get some time this weekend. Otherwise I was on cloud 9 with how the rust removal was coming, this is without any metal prep or clean up, just step 1 wire wheel

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