Cab Rust cleanup

[Ulfhedinn]

As you can see I have some rust damage. I assume some of this will have to cut out and replaced with new metal. How should I prep the clean up of this. First time doing this...

Do I need to sand it tell I dont see anymore rust or until its flat or ?

I have a drill with a bucket wire brush <not sure the name is correct>
Random orbital sander with some 60Grit currently.
What else do I need to purchase.


My plan is POR-15 treatment aka Marineclean then prep & ready followed by Por-15 followed by Al's Liner Heat and Noise Reducer followed by LineX or a do it at home brand.

{Cant seem to attach pics.. working on it}

 

[Ulfhedinn]

More pics

 

[Ulfhedinn]

last but not least

 

[4x4orbust]

some of that looks like surface rust, and can be dealt with without cutting it out and replacing it. do you have a grinder? a wire wheel on a grinder does a good number on rust. then treat it with your choice (por 15 it seems).

my motto usually is if there isn't a hole (from rust) wire wheel/flap disc it, por 15 it, and paint it. if there is a hole, cut it out and replace with good metal. i see you have some bad rust around the door jambs, that will need to be cut out and replaced. rust like that (big flakes of rust coming off) spreads fast in my parts.

 

[Polski-Chevy]

^^This^^

My late model chevy has more rust than that!

Your in real good shape if it's not rusted thru. You don't know how lucky you are to be located outside of the rust belt. I am jealous

 

[AJMBLAZER]

I dunno. Some of those seams look pretty crusty. I'd definitely check and see if you can see the bottom/other side of some of those. These things usually rot from the outside/bottom in/up.


I'm just saying because I've had bad luck on other vehicles with thinking some crust was just surface and then finding there was nothing but crust left...

 

[Ulfhedinn]

There is a couple of really thin areas on the cab floor. I assume I will have to cut and weld in some new metal in those spots.