Rust repair-stripping-grinding

I have started some rust repair on the floor pan drivers side of Ole Yellar.Seems that is the only area with rust.The previous owner did make the classic mistake of pounding down apart of the wheel well to make more foot room and tore the wheel leaving a hole.Being at that time the van was in Florida,I guess he didn't worry too much about it.So moisture kick up in there and the sound deading material collected the moisture like a sponge.I'm in the process of tearing out the rubber mat and both seats.I have a ruff cut of the hole and now are finding pin holes in the pan by the gas peddle.I'll get some picture up in the next couple of days.

My 3" cup wire brush was pretty worn out and I wanted something more to clean to bear metal.I bought a 5" cup wire brush and really I'm not happy with that.It's slow going not really cleaning like I want.I am guess you guys are using a D-A sander for that,but don't know.Need some suggestions for that and if it is a D-A sander what grit are you using??.

Thanks in advance,

Gary

use a knotted 3inch cup wheel on a angle grinder. D.A you can use paper to 36or40 but your not going to clean much with it better to stick with wire wheel or a mule skinner wheel we used this wheel when we clean up metal before leading

For small areas I have a small sandblaster I hit it with, scrub it down good with Phix and a Scotch-Brite pad, then when the Phix dries, hit it with a coat of epoxy primer.

Sometimes with just straight ol' sheet metal, it's just easier and quicker to whittle out that piece of rusty steel, weld in a new piece, epoxy it, both sides then undercoat (I prefer truck bed liner). You then don't have encapsulated rust - which never sleeps - that without media blasting will remain to some extent.

I agree with Dave sandblasting is the best way. small hand held units are avaliable and work well for this, and are a lot faster

Clean it with the wire brush as well as you can then use the POR system on it. Problem solved.
POR-15 ® Rust Preventive Paint - Stop Rust Permanently