Good Power Sander

[Maritimer]

I'm looking to get under the truck and sand away rust on the frame, prep the surface, and then repaint.

It's definitely not a one day task, and I want to be able to basically target a single area and do it bit by bit. The paint doesn't need to be pretty, and I'm going to brush it on because I hate using spray paint.

Anyway, I need recommendations on a good cordless drill tool that I can put all the appropriate attachments on for getting small angles and little holes, etc., and that can handle metal. I'd like something that is not too heavy-duty as far as power, as I'm not comfortable with power tools. Just something to get the job done well. I used an angle grinder last year to cut off an old trailer hitch and it was rather scary.

Also, I'm really a know-nothing about this, so I was wondering what kinds of sander attachments you'd recommend as far as grit or roughness.

 

[Nervo19]

I'm not sure how bad your rust is but I really don't have any on my 3rd gen! I do have an '89 that had a bit on the under carriage. I washed it, put navel jelly on the rust, waited a few hours and power washed it. I then used "Rust Converter" and "Rust Encapsulator" by Eastwood. They are in a spray can so it was easier to reach the under carriage. I think these products are similar to POR-15 that everyone raves about.
If I had terrible rust I would find a way to sandblast it.

For sanding the rust and body work topsides I got one of the cheap random orbital sanders from Walmart:

http://http://www.walmart.com/ip/Black-Decker-Orbit-Sander/896337

and in the place where the bag hooks I hook a tiny wet/dry vac from Sears/Kmart. They are usually about $24.00 near Father's Day.

http://http://www.sears.com/shc/s/p_10153_12605_00917611000P?prdNo=1&blockNo=1&blockType=G1

Sorry I can't seem to copy and paste pictures. This combination works well and the vac collects a lot of the dust. I know you said "cordless" but most cordless batteries aren't going to last long enough to power a sander unless you get something expensive. I got really long power cords and added a strip to power the two tools. You will also need lots of 40-80-120 grits sandpaper with holes and get extra vac filters. The lower the grit the rougher the texture. I'm currently on my third large project in two years with this combo and it hasn't burned out yet. You will need eye protection and a cheap dust mask because the rust flies. I hate using a grinder too! I only use mine to cut metal or grind welds.

 

[IFNg]

For the larger/flatter surfaces, try this out (Norton strip disc):

It does a good job of removing paint/rust without getting into the metal

 

[Maritimer]

Cool. Did either of you guys ever have luck with a rotary tool with various mini-attachments?

Sanding

 

[Nervo19]

I have a dremel rotary as well as a dremel muti-tool (rip off of Fein multi-Master). I would never attempt to do a large project with the Dremel rotary. It would take forever! And again the rust/bits of metal fly. I've mostly used mine for cutting heads off bolts and shaping pinewood derby cars. It would be POSSIBLE to use. The heads will need replacing often so it might get expensive.

The Norton Rapid stripper posted above is a great choice but again it goes on a grinder which you said you don't like using. They do make version that will go on a drill. If you decide to get a cordless drill get a nice expensive one. I got a Makita and it stays charged for a very long time. You can get them cheaper via eBay.

There are many ways to do this, you just need to research. Try searching "rust repair" in google images and read up.

 

[Maritimer]

I was window shopping today at the hardware store, and most of the attachments I want will fit on a drill, so I'll probably get a drill sometime soon. There are also some attachments for angle grinders, and I guess I can use it for the heavy stuff. They don't bother me too much when I'm just doing surface grinding. I was using a grinder to cut metal last summer and was terrified the disk was going to shatter or something and kill me.