Advise needed: Rust removal / treating products or techniques?

[Turbodave]

I'm in need of a little advice regarding the best rust removal/treatment products or techniques. Currently I'm plodding on with the Cavalier's chassis, so far I've scraped off alot of the original underseal in order to see how bad things are. Thankfully they aren't too bad and one the whole, it's really just a few areas of surface corrosion on the legs and around bodyholes and so on that need dealt with.

A picture speaks a thousand words, so this is where I'm at...





So, it was my plan to...

1. Scrape off all the original underseal and seam sealer (where required)
2. Wire brush attachment on the grinder and buff back the surface corrosion
3. Treat said areas with a suitable product to kill/convert the rust - suggestions?
4. Etch prime/Red oxide the areas
5. Reapply the seam sealer where required
6. Coat in a rubberised, high adhesive underseal

So, really I need some advise on what the best products are to use. I've so far been advised to use POR15 to treat/coat the rust or Bilt Hamber but having only used Kurust and Genolite in the past (with varying degrees of success!) I'm unsurew what the best rust killing/curing product is?

Then, underseal. Again, I've used Waxoyl Underbody Seal but found it to always remain a bit tacky and oily looking and that's not what I want. I've also tried A more rubberised underseal which gives a much nicer finish and goes totally dry. But, again these are just generic off the shelf types from Halfords to need something better.

Finbally, internal box sections and so on such as inside the chassis legs... again, I know there's a Waxoyl product in Halfords but does this actually kill any rust or simply give a kinda of waxy protection? I don't want to be sealing any rust in, I want to try and kill it but also add more protection.

So, any words of wisdom or product recommendations?

Cheers

[keithcdb]

Kurust is fine, also waxoil mixed with a bit of old engine oil works well for prevention.

This was recomended to me Rust prevention | Rust treatment | Rust proofing from Dinitrol UK supplier

As was Rust treatment, rust inhibitor, industrial coatings, rust removal, Rust Bullet

But the the cutting disc is the only real answer to rust lmao

[Turbodave]

Yeah I know, cutting it out is the only way to get rid 100% however that's not really possible when it comes to the rear end of a Cavalier! The wire brush will take it right down to shiny metal however where there's been surface rust, it leaves it rather pitted and whilst that's not an issue as a few coats of underseal will cover it... I have found that if Kurust is painte don then it's primed, it starts to discolour rather quickly hence I'm not sure Kurust is the answer. So, need something to paint onto the bare, pitted metal to stop the rust in it's tracks or at least slow it down. Dinitrol was mentioned by a mate too, so will have a read and give it a shot.

Cheers!

[keithcdb]

Yeah I know, cutting it out is the only way to get rid 100% however that's not really possible when it comes to the rear end of a Cavalier! The wire brush will take it right down to shiny metal however where there's been surface rust, it leaves it rather pitted and whilst that's not an issue as a few coats of underseal will cover it... I have found that if Kurust is painte don then it's primed, it starts to discolour rather quickly hence I'm not sure Kurust is the answer. So, need something to paint onto the bare, pitted metal to stop the rust in it's tracks or at least slow it down. Dinitrol was mentioned by a mate too, so will have a read and give it a shot.

Cheers!

Meh, just buy a new shell

[Dave Hay]

wire brush aint enough

grinding stone to bare metal then treat

the above looks like surface rust on the chassis but some of the rest will come out in nice pin holes!

[Frisco]

Id remove that spring seat and check the chassis rail under it. Ive seen ones that look better than that be holed unberneath