Hi
Yes i tried kurust but to be honest, i wasn't overly trusting of the dark blue colour thing being a permanent treatment against the rust. Something just didn't seem right about it.
I also used Hammerite Rust Remover gel yesterday.. apparently brings it back to bare metal.. except that there was still loads of rust showing!
So I went back to halfords and bought more wire brushes for the grinder and drill. The bonus with the drill is that it spins in both directions so that when you're working near and edge, you can have it spinning off the edge instead of against it - the angle grinders are lethal when hitting and edge. Several months back mine caught an edge, flipped off it (and out of my hand) bounced around the ground before landing right next to my ear - EEK! I soon started using the 90 degree handle again lol.
Anyhow today i wire brushed the hell out of this bit of metal (the phone shaped bit bolted onto the front sub frame) and then hit it with jenolite.. now oddly it then looked rustier than ever after using it but as per instructions i wiped it off and then painted over it with (zinc) primer. It's now in the shed drying and will get finished tomorrow.
Then I will work on the front sub frame and other misc rust spots. Got plenty of underseal and waxoyl now so hopefully this will put an end to all the rusting. What I then need to do is the other bits like wish bones, shocks and brake calipers... oh and the rear end of the car including that sub frame
Not entirely sure how to do the top side of the sub frames.. the last time i removed a front sub frame the two massive bolts snapped. I got the sub frame but half the bolts were left in the chassis of that car. If that happened to this car I would be proper stuffed. For the time being (and just to get the car road worthy) I think I'll just do the underside of the sub frames and worry about the top side later. As long as I can get everything underneath undersealed and waxoyl'd then i can get on with the engine side of things and put it through the MOT!
The ECU is shot.. which is the reasson the cooling fans have not been working so I am going to use an arduino processor and temp probe to get around that and activate the fans that way. Not ideal but it will have to do..