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I found a used original I'll make work, (cost savings) figure I'll paint the top side but how should I deal with the under coating? do I need to sand down or re coat ??
I'd try a stiff wire wheel on a grinder. It should get all the rust off and do a pretty damn good job on the undercoating too. Then just spray or roll with an good rust inhibiting paint like POR, Zero Rust, etc.