sand blasting or using a flap disk
#4
I think it would depend on the size of the area you need to work on. A small area can easily be cleaned up using the FD. A large area may be easier and quicker to clean up by blasting. Take care as the use of sand on sheetmetal panels can cause warping and pitting.
#6
Sand or blast?
Blasting with sand will remove all traces of rust. Blast with milder media like walnut shell or corn cob will not. If you are not going to weld within an hour or two of sandblast cover the area to be welded with weld-through primer.
#8
Also, be sure the metal is good and clean, after you media blast, if you go that route. And, don't forget weld thru primer if you are over lapping anything, or will have no access to corrosion protect the back side.
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