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

I've used a soft grade wire wheel brush to get rid of rust. If you have to get a sander, go for a dual action orbital. They come in electric and pneumatic models. They are the best at not leaving a sanding pattern.

Definitely primer over clean bare metal. If you're using a rattle can, use no more than you need to cover the area. It will have to be sanded off when you put automotive grade primer on the car. Some auto primers will not adhere to the rattle can stuff very well.

Caution about the wire wheel brush.
1. If you hit body filler it will dig down into it.
2. Use a new wire wheel on some heavy metal, like the K-frame first. This will set the direction of the wires.
3. Once you get the wire wheel "set", DO NOT reverse the direction of rotation. If you do, it will dig into sheet metal until the wires "re-set" their direction.