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I have used por 15 on seveal pieces of my 67 project truck and I am quite happy with it, however I have yet to test it as my truck is still under construction. I used it on my frame first and the paint is tough as nails and looks good. to answer your questions:
1)You must atleast remove all of the flaky rust as well as all dirt, grease, and other contaminents. Its designed to bond to rust so if you have a rusty metal surface that has been brushed with a while wheel it should be good. However, I have strayed from the recommended practice by putting por 15 on bare metal. Just make sure it has a good amount of tooth or scuffs to bind to. The stuff seems to stick to anything. The main thing you want to stay away from is putting it on other paints, it won't stick.
2) I would use what comes in the kit, it defenitely can't hurt. Again you must make sure all of the loose stuff is taken off and everything is dirt and grease free.
3) The metal prep will flash rust after you wash it off so it helps give a bit of rust to bond to. Its up to you if you really want to do that, but I would recommend following the directions since what I have done is not tested or proven.
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07 F-350 xlt 6.0 PSD LB CC SRW 4x4, black on tan, A/T, 5" exhaust w/4" downpipe
67 F-250 Project truck, currently in a billion pieces
70 F-250 4x4 (highboy)
Past trucks: 04 F-250 xlt 6.0 PSD SB extcab 4x4, 6spd, all stock and 97 F-250HD xlt 7.3 PSD extcab LB 4x4, 5spd, Superchips tuner, 4" turbo back exaust, K&N CAI, 02 intercooler installed, Sold
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