I spent about a day and a half with a variety of wire wheels and sander discs; I could easily remove the light rust and usually the original paint. What I couldn't do was get into all of the nooks and crannies, and couldn't leave any significant tooth on the steel. Reluctantly, due to schedule and funding limitations, I've concluded that I'll need to take it to a sandblasting facility. The chassis is thus sidelined awaiting said funding. I've since started destroy... er, fixing the cab.
After flip-flopping for months, I broke down and purchased paint; I chose an epoxy primer and urethane single-step topcoat. Was it the right choice? I don't know; ask me in a few weeks after painting, and then ask me again in 15 years or so. Certain folk were adamant recommending something like POR-15; others in regard to the epoxy primer/top coat approach, but no real consensus. Just a mental coin flip; no real rationale for the choice.
Last edited by DougE; 09/09/10 09:39 PM.