rust removal

I suggest a wire cone wheel on a cheap harbor freight right angle grinder. I have used mine like 1000 times. Then after that. The ospho mentioned, probably applied with a stiff plastic brush or something to get it down in all the pores and crevices of the area. I believe all the rust converters use the same chemical. Third, I would use 2 part epoxy primer over the ospho.

SPI makes an outstanding epoxy primer. Very durable and I like 2 part because it will harden even if you get it on heavy in some obscure areas like a crevice.

http://www.southernpolyurethanes.com/

I sand blast anywhere possible but it is messy as hell and ruins things that are in secondary or reflected range, like sand bouncing off panel onto glass etc. So, have to protect all that you aren't blasting.