Auto body repair & detailing: Rust removal, rust holes, surface rust


Question
QUESTION: Hey Josh - My wife and I decided to tackle building a rat rod for the first time. I have a 33 Essex body that we pulled out of the bush. It is in pretty good shape but is obviously covered in surface rust. What are the best methods for removing the rust on the flat surfaces and in the hard to get to places. Two things to keep in mind when you have time to answer: 1) I would think that dipping it would be the best/easiest way but we don't have that kind of money! 2) This is going to be a rat rod so the prep doesn't have to be perfect.

Cheers
Karen & Don
ANSWER: Don on a rat rod most people leave the rust spots,i have even seen a fiberglass body that a guy drilled holes every where and had airbrush work on it to make it look like rust holes, but if you do want to fix it just grind the surface rust down so its no longer there and the holes cut them out and make a patch panel and weld it in.if you need help doing the patch repair let me know.

---------- FOLLOW-UP ----------

QUESTION: Thanks for the quick reply. I guess I didn't ask my question quite right. I was looking for a more specific answer to getting the surface rust off. The whole body is covered in surface rust and that is what I want to do something with before I spray it flat black. I was looking more for a specific suggestion for removing that such as:
* using a grinder on flat surfaces (if so, I am assuming one doesn't use a regular grinding wheel as you would be removing metal as well)
* some chemical that can be used (especially for the hard to get to areas)
* sandblasting
* or is it just alot of sandpaper and tackle it by hand or with an orbital sander

Thanks again
K & D

Answer
K&d yes you do use a regular grinder they make different grit grinder wheels you will need 80 grit it is going to remove a lot of the metal around the area of the rust just don't let it dig in keep the grinder moving left to right,and then go over it with a orbital sander start with 80 grit then move to a finer grit until you get to about 320 grit, chemical are way to messy and don't work as good so i try to stay away from them,never sandblast the outside of a body it will warp the panels unless you have it soda blasted it will work.