Warning: there more be more than one way to go about doing these things. I'll give you my ideas - others may be better!
How long? ASAP!!! Depending on humidity of shop - how many times you touch it, etc. Basically - it will start happening right away. Here in East Wa - Ive had bare metal sitting in my garage for several months with only surface stuff showing where I touched the cab with bare hands. I do not recommend letting it sit long.
Instead of zero rust, you can also shoot with an epoxy primer or self etching primer. Those will serve as a protectant and prep the metal for sandable primer (PPG product called DPLF can be used for bare metal). Given that you are in Arkansas - I would cover that metal the same day you get it home.
Blast first - then weld. That way you know what you're working with. After blasting you may find that some areas are going to be very thin (formerly heavy rust areas) and you would need to be cautious with the welder as to not blow through. If it's not 100% clean prior to this - then you cannot be 100% sure of the quality of the material.
To prevent my wife from going mad - all I had to do was put the truck in her name!!! Now all my research and time in the garage turns into time that I'm actually spending for her!!! Of course the agreement is that it is her truck - she will drive - she chooses colors and designs and all the goodies. I just get greasy - well not anymore (it's all new and clean - this is the way working on a rig should be)!
In my link below - you can see the process of what she looks like before and after blasting......
- Ryan
