Today I was intending to strip my driver's side sill back to bare metal, de-rust and then repaint.
I got as far as stripping to bare steel and removing some of the rust but didn't have time to go further before daylight went.
The procedure I'm using is: BARE STEEL > DEGREASE > DEOX GEL > DEGREASE > ELECTROX > EPOXY PAINT > DYNAX
I've got as far as the first photo below but didn't have time to get rid of the last stubborn areas of rust in the badly pitted areas (up until then the flapper disc and Deox had done a pretty good job of getting rid of a lot of the rust).
I've brushed the bare metal with a light coating of Dynax until I get chance to work on it again in a week's time. The car will remain garaged till then.
Is this the usual way to deal with bare metal when you can't get the job completed in a day? (Sorry for silly questions, but I've never really done any bodywork before).
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Also, I get the feeling that some parts of the rust in the photo might be too stubborn to get off at all. Would it be foolishly sloppy to accept defeat and paint over them, knowing that at least I've got the bulk of the rust off?
Another question: I've been using a flapper disc+angle grinder to get most of the paint off. Is there any risk that if I'm over-zealous with it I might thin the steel out too much? I'd got the impression that flapper discs were only abrasive enough to remove paint but it was giving off quite a lot of sparks (presumably removing metal). There are two small areas where tiny holes appeared by the time I finished (like the hole in the attached pic), although I'm not massively worried about them.
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