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Thanks for the info guys. First of all I will be removing the body as the rust on the frame is extensive and needs to be dealt with one way or another including under where the aluminum folds around the tubes. I have an additional problem in that the PO decided to improve the car a bit and cut off the engine mounts, steering mount, and a couple of outriggers so he could replace them. With that going on, I am not sure when to do the rust removal/stabilization. I realize after welding the new pieces I will need to do final painting/coating, but I would like to be working on a reasonably clean frame while fit checking everything.
David, Thanks for the info on the powder coating. I did not realize it had to be bare meatl, so I will factor that into my thinking as I decide to move forward. I'll try to post a picture later of what I am up against in case that helps jog some more ideas loose.
Jay
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