Rust Removal

[breckbone]

I want to begin removing a bit of body rust I have on my 68 FJ40. It's not a ton, but I've never done anything remotely close to this before and it seems a bit frightening. Basically there are two spots. On the seams below the driver and passenger side door. I've read about different kinds of brushes (nylon vs steel) to get some rust off, but I'm not sure if that's the best way or not. I've read a bit about the electrolysis method but am not going to be able to dump my tub (still on frame and not going to be removed for the time being) in a bucket of water.
I have a friend that said he'd weld a new piece of steel on if I did all the prep work. Is there a thread that I've missed in my searches that covers this prep work? Or is it just basically grind off all the rust w/a drill and a brush 'til it's all gone,then weld, sand, prime, paint?

Thanks for any info you can toss my way!

 

[rockcod]

Check out this thread https://forum.ih8mud.com/showthread.php?t=104821

He has done an outstanding job with a rusty cruiser, bringing it back to life.

Good luck with your project!!!

 

[Pygmalion]

It all depends on how deep the rust is.

If it's surface rust, just sand down through the rust to bare metal, or if it's pitted, a small sandblaster will help get the rust out. I'd then spray the area with a prepping solution (I use Phosphoric Prep & Etch), which will remove any remaining rust and etch the metal for new paint. Then you can refinish the metal with priming and painting (and body filler if needed).

If the rust is deep, then you're talking sheetmetal fabrication. The thread provided by rockcod is excellent.

 

[brownbear]

Sandblaster using glass abrasive works nice. Stay away from the slag abrasives. They leave a bit of weld slag in the metal. Might rust later.

But the glass seems to work good on cruiser metal. I worked my doors really hard and never had an issue of deforming the metal.

Also afterwards you need to use a chemical rust disolver to get all the little grains of rust out of there.

Sanding rust down only blends it into the metal. It will rust again.

I used POR-15 to help seal the metal afterwards too. Then did all the normal coats after.

 

[5280Hawk]

That guy is a surgeon.

I was just looking at the pages where he's cutting out the rust and patching back in. Rediculous.