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I have a guy ready to sand-blast my truck for me and he says he can do a good job without taking off the front clip - just pulling the motor, wiring etc. I'm not sure I'm comfortable with that approach - aren't there some hidden areas that could need attention that you can't see without removing inner and outer fenders? Not to mention being able to do a better job on both sides of the inner and outer fenders? I'm particularly concerned that I find everything since I have that one rotten out driver's side cab support and part of the stepwell. Thanks again in advance - you guys are the best!
I would remove the front sheet metal before beginning any blasting, it will make for a more thorough job and repairing any metal will be much easier to get to.
Your starting out right with the blasting but unless every crevice, every pocket of rust is removed, it will be back. When your blasting is complete I would etch prime or epoxy prime all the exposed metal, everywhere except where your repairs will be.
I would further recommend the use of an air operated body saw when cutting out the damaged sheet metal. They are fairly inexpensive and do a good enough job that the removed metal can be used as a template to cut your replacement metal by. When your repairs are complete wipe down the exposed metal with an automotive ‘wax and grease remover’ and finish priming.