Best method of killing rust...

[rustbucket]

So with the help of you guys and the rest of the internet, I'm quickly learning how to get started on restoring my van. The problem is that I'm confused by the infinite amount of ways to attack the rusty parts of my van, and if you've seen my other post you'll know that it's in quite a lot of places.

I've read about so many different products and methods of getting rid of rust, but just want to know what you guys feel is the best approach? Would you mind explaining in as much detail as you can be bothered to give.

Firstly what if the metal has eaten right through the panel? Do you approach it differently depending on the size of hole, or do you recommend always welding if there's even the slightest hole?

Also, surface rust... what's your method?

I'm really new to it all and there's too many options for me to know which is best. Ideally I'd like to do the best job I possibly can, but that's dependant on how much time and money the best method costs.

Thanks

[kevtherev]

rusting or oxidisation of iron is a chemical process.
removing the oxygen will stop the process dead.

it's as simple as that.

[boatbuilder]

If the rust has gone all the way through, then I always cut out and replace it. If it is only surface rust or minor pitting of the surface, I grit blast it thoroughly and treat it with phosphoric acid, then I clean it and apply epoxy primer. Very important to de-rust, treat and paint BOTH sides of the repair. Same rule applies when welding in new metal.

A lot of people use vactan instead of phosphoric acid. Personally I don't have a lot of confidence in Vactan as it covers up the metal and goes black so you can't really see if it has fully converted the rust.

[CovKid]

Yep but it goes clear on anything thats not rust.