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Re: rust sucks
I would just sand it down, prime it with self etch primer or epoxy to further stop the rust, from either starting or coming back through, then paint it. if sanding doesn't work try a grinder or wire wheel. Maybe even por-15 or something.
As for the intake if it's alum. I used some brake clean and a brillo pad on mine, it was just reg. alum. not polished or any fancy coating and once done it turned out very nicely, like brand new. it had dark spots and stains from a leaking thermostat housing when I cleaned it, also had it off to do so and get all the little areas. Even had overspray on it, now it's all clean like brand new.
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