Rust and determining what to do.

[Pixel]

Rust is sure a pain in the neck. I certainly don't have to tell anybody here that. If a machine has accumulated a lot of rust in the cooling compartment, how do you determine if you can just sand it down a bit and repaint it with maybe a clear coat, or if it has to have serious rework? Obviously a visual inspection is important, but how do you tell surface rust from a more serious problem, like it's really starting to rust through?

I'm sure I sound very silly asking this question. I've never been mechanically inclined, and by extension have not dealt much with metal rust and repair/reconditioning.

[ClassicCokeLover]

Best method is to have it media blasted. It answers all of the questions as to how much good metal is left.
But your first step should be to see if you can poke through it lightly in some areas with a small screwdriver or awl. Inspect both sides of the metal to determine if you can see if it rusting through, or if it is just surface rust.
 

[MoonDawg]

       I've probably handled over a hundred machines in the last decade, most had some sort of rust on the floor....but only 1 had to be welded.