Wearing out is not an issue with flap wheels, they seem to go on forever. They work well, fast and leave the metal with a "bright" finish but also leave the surface with a rough "adzed" finish". You can't get into corners and crevices with them.
A wire "cup brush" is bit better in corners but doesn't leave a bright finish. It gets the surface rust off but the metal is left with a sort of brown film. Needs "Kurerust" or similar treatment prior to painting.
I'm surprised, but open to persuasion. Most of my experience is on fairly badly pitted rusty metal, on this my feeling is that a wire brush will tend to get further into the pits. In general if this is the first stage of 'rust treatment' then whether the surface *looks* good isn't very important, what matters is if the 'paint' applied after can penetrate to solid metal.
It gets the surface rust off but the metal is left with a sort of brown film. Needs "Kurerust" or similar treatment prior to painting.
Kurust is now a useless product since it was been bought by Akzo Nobel (new owners of Dulux), and reformulated as water-based.
get it professionally shot blasted if at all possible and then paint or spray with zinc-rich primer immediately.
Akzo Nobel also now own hammerite and have turned that into just another paint. Previous formulation needed Xylene to clean the brushes. New version doesn't, and is nowhere near as good as it was. In fact you'll struggle to find any decent metal paints these days.
I've never found any chemical treatment of rust works as well as grinding back to bare clean steel. At best, it is merely better than painting over the rust.
I had a rusty sunroof on the old Rover. One of the few panels you can't buy new.
Sanded it down to bare metal, then used a Dremel type thing with a diamond burr to grind out the pits. Then lead filled it. It cost 100 quid to have it painted, so wanted the paint to stay on as long as possible. ;-)
To me the difference is between a light coating of rust which is easily removed anyway, and the sort of bad pitting you get on say an old car panel. The difficulty being any treatment penetrating to the depths of that pitting. Because if it doesn't, the rust will simply spread from there. Obviously some paints will be better than others, but none gives a satisfactory life IMHO. Like as long as with brand new rustless steel.
And how long did it last before rust appeared again? The snag with any of these sort of things is knowing for sure it is any better than a plain decent primer.
Or makers hiding behind such 'requirements' as an excuse to make a cheaper product and sell it at a higher price.
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