I took a look under my truck yesterday and the rust on the axle housing is looking pretty bad. I've been thinking of yanking the bed (which is actually in decent shape) for a while and getting at the frame, but it looks like I should drop the axle too and get the rust off it-I'm just afraid of what I'll find once I get the flaky crusty stuff off. Planning on using an angle grinder (lightly) and then going over with a knotted wire wheel. There's a NAPA near me that is a dealer for POR-15 but I've heard good things about this stuff too:

http://www.hirschauto.com/Miracle-Pa...er/products/3/

 

Actually a common issue.
You might wanna start with the wire wheel first just to be sure you don't take off too much metal.
Depending in exactly how much rust you have you might just be better off finding another housing

 

Easier said than done-in NJ they all look the same

 

I can`t see how it can be a Common issue .

I have been trying to buy a rusted out housing for a few years within 200 Miles of the Allentown area .

If they are rusting out it is people that don`t visit forums

I have been using CGW EZ Strip in 4 1/2" They remove rust but not metal

Along with wire wheels on the air dye grinder

Clean it up see if it leaks

I have a really good idea on how to repair these.

Your not faraway

I might have a housing you can have if it is the correct size .

 

I scrapped an axle just due to it being rusted out. The third member was in great shape but was concerned the axle housing was going to be a unsafe to use. It was a rust bucket truck.

 

You can use Hydochloric acid to remove rust rather easily chemically, but if you are the slightest bit clumsy you might want to try a weaker product such as Muriatic Acid because hydrochloric acid is very painful if it comes into contact with your skin.

If you want to remove the rust mechanically, I would go with a media blasting. You can get a cheap Harbor Freight blaster for around $75, but get good glass media such at Black Diamond available at Tractor supply or it can take forever to cut through the gunk.

I blasted my entire truck (frame, chassis and axles) when I was restoring my 83 pickup and it was the perfect (and recommended) substrate for POR-15. I brushed on two coats of POR-15 and sprayed the third. Then sprayed two coats POR-15's Chassis Coat as a top coat while the base coat was still tacky (have to top coat it or it or the rust preventative paint will deteriorate under UV light). It took about 2.5 quarts of POR-15 Rust preventative and 1.5 coats of Chassis Coat to do my entire frame, axles and driveshafts. POR-15 may seem expensive, but a little bit goes a really long way. The stuff is rock solid, durable and looks good - I am very please with the results.

Here are some pictures of the stuff I did:

 

WOW-that is some seriously nice work!