how to prep/clean metal?

Go to your local auto paint supplier and buy some red scuff pads, a gallon of cheap lacquer thinner, a couple rolls of those blue shop towels, a squirt bottle and some metal conditioner and some chemical resistant gloves like you'r use for furniture stripping.

Use protection - gloves, goggles. Make sure you have adequate ventilation or use a respirator. NO SMOKING.

Using the scuff pads and the thinner go over a panel at a time wiping down as you go with the towels to remove oily residue.
After that drys, read the directions on the metal conditioner and dilute it as required. Again using the scuff pads clean each panel in turn, WIPING off the liquid - don't let it dry on the panel.
The conditioner has phosphoric acid in it which will etch the surface and leave a coating that will discourage rust and give the primer something to grab onto.

Now days you want to use catalized primer. Don't mess around with the stuff that only needs to be thinned it will not provide a good foundation for subsequent layers.

Hmmm. In all these threads it seems to come down to "visit your local supplier" which seems like damn good advice. I'll be needing to do the same thing as my car has ample surface rust but no holes. I dont want it to get worse with winter coming as it will only be in a carport.

I have seen these little cans of aresol that you add to your own mixed paints/primers in a glass bottle. It allows you to spray good quality paints, if you dont have the proper compressor or guns. In the end it may be more expensive than buying the correct equipment, but it still may be less than buying spray cans of dubious products which will have you starting from scratch again. Find that local supplier and listen and see what they recommend. Let them know this is not something you'll be doing often.

Also, I found local paint and auto body shop that repaired a rusted thru fender on my 02 dodge ram. They cut out the arch, welded in a new one (showed me the old piece), used rust preventitive on the back side, sprayed to match my stock blue, all for $300. Other shops had quoted up to $900. I honestly can not tell where they sprayed and where they didnt, a very nice job and blend. There are guys out there with less overhead and can work within your budget. I plan on doing the prep but may let these guys do the finish paint.

Yo chillin, that's por stuff is great. A good buddie and me did all the control arms and cradle on his m3. It's is phenominal. You jus have to reelie really clean up the surface well. U can roll it on with a bush or roller whatever. Bu for the best results is spraying IT with a gun. That's what we did. And you can see yourself in it after two nice healthy coats. I will be using it on my frame off 78 boo. That's stuff is the great. The claim that because of it porus or non porus whatver paint properties u can hit it with a hammr and it won't chip. So we tried it. And It is true. U really can. It's expensive. But worth it. If u r dealling with alot of rust. Make sure u get atleast 2 bottles of there metal prep. It's woks great. It takes the rust color right out. Good luck!
G bodys rule.

lol, i was on my iphone at work and didnt even notice the date.. #-o

but i glad to hear you had great success!!!! \/