It has been a while since, I was in this stage at the time of this post.
There was a time that I thought my bus was scrap due to rust.
I was crushed.
I looked here and asked a few people and checked out my frame and other critical areas.
Once, I resigned myself to reskinning my bus and replacing a few floor sections, I got to work.
The floor below the driver seat was bad, same with the rear wheel areas. One wheel well was pretty much destroyed.
I replaced it all.
As far as rust, it depends where it is and the level of rust.
I spent a ton of time with a wire wheel on my grinder, removing surface rust from the floor of my bus. Some was pitted, most of it was very minor surface rust. A lot of nasty dust, wires flying off and stabbing into your arms, legs and torso. Once, it was done it was amazing.
The best rust removal tools I have found are;
Physically removing the rust with a grinder disc, wire wheel and replacing bad metal.
I tried rust removers, chemicals, treatments, sprays, everything with little or not real success. A bath solution would work wonders if you could drive your bus into twenty thousand gallons of rust remover haha.
Don't give up on your bus. If the frame is good and the mechanical aspects are good then stick with it. The body work is not bad at all in hindsight. Replacing the skin was a learning experience but well worth it. I replaced it all and primed it white with oil based primer and a power sprayer. Did a roof lift and currently I have no rear wall. This weekends project is the rear wall structure and framework. Followed by new skin in the upcoming future.
I went from a red ring on the ground around my bus to bright beautiful white everywhere. Well, some gray too but mostly white. A very impressive transformation for a eight month project so far.
So, keep it up and don't hesitate on asking for advise or if you need to vent. We are all in this together and it should be a labor of love.
D.L. Jones III