Yesterday I completed the rust and paint removal by breaking out my Compact Air Needle Scaler - picked this up a few months ago when it was on sale for about $20 at Harbor Freight (http://www.harborfreight.com/compact-air-needle-scaler-96997.html). I also have a full-sized unit but it wouldnt fit inside the cabinet sideways, so I was lucky to have the "mini-me" sized version.
Ive never tried using one before - had only heard about people having success when them in rust and paint removal. This pneumatic tool vibrates a series of fat, wire-like nails that force paint and rust off metal. It worked extremely well, especially for the corners and inside edges that I couldnt get to with the wire cup brush. I followed up with a tiny bit of media blasting then worked everything over with a dual-action sander. Finally I shot the whole thing with some primer.
Initial layer of Primer
Finished the primer around 3:00 PM
Today I took out the case and took a more critical look at any bad dents and scratches, which lead me to a some light bondo work. I hit the low
spots, waited for it to dry then worked them out. Im not looking for perfection so there are still many small spots - most will work out with some light sanding. I just knew that when I shoot the gloss gray on it that the larger defects (which are mostly dents) will show under my shop lights - so the effort was to make things better (A.K.A. minimum effort) and not worry about perfection. I didnt bother with the inside.
Light bondo and sanded out
I then re-sprayed the whole case with a second coat of primer and this is the result:
Once it was dry to the touch I brought it inside to completely dry and set-up. I guess its time to order the bearings and belts.
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