Reply To Thread Removing heavy Sheet Metal Rust and sealing. (pics)

Apart from expensive media blasting, you can either buy yourself a small inexpensive sand blaster gun with a cup on it (for cleaning the deepest areas of rust) and use an 80 grit round grinder disc on an electric buffer.....you can pick up what you need at Sears usually.....or check your local body supply for the discs...usually 7" to 9" round discs that attach to the buffer like a buffing pad....somewhat flexible so they won't gouge your steel.

If you work carefully with an 80 grit disc, you can do a pretty good job......One fender etc. at a time, followed up by a good self etching primer. Don't let the bare metal set....get it primered......self etch or good epoxy primer.....and when you grind, you'll discover the dings and dents you didn't see so you can fill them properly.

You can smooth out the areas that were ground with very light coats of plastic body filler (after roughing up your primer)........let it dry and block sand with 80 grit 'til she's smooth again.