[asphaltburner]

Yo! Bummer to hear all these problems with POR. I'm familiar with it by its' reputation, but have never used it due to its' expense. I found Martin-Senours' Rust Stabilizer long before I'd heard of POR and it's cheap, works perfect, and can be applied to any metal surface with tremendous results and nearly no prep.
The cars I've used this on are daily drivers so they're exposed to extreme conditions and my '68 Mustang commuted for over 70,000 miles before I parked and covered it, and it's rust stabilized areas have never showed new rust.
My '76 Camaro has been on the road for over 30,000 miles after I stabilized and repaired seven lower external spots on it without rust returning. Some were holes.
I dared myself to return a '66 Mustang to the road,...I had to perform EXTENSIVE bodywork on it back in 2000, including holes in all four floorboards, and it still has not had rust re-occur.
The water soluble rust stabilizer is available at NAPA and adheres to nearly EVERYTHING (including skin, beware!), drys quickly to a black primer, but must cure for 24 hours before painting. I find a spray and paint on product, but I much prefer the paint on product as it does a better job of stabilization. FRANKENTRUCKs' floors have small repairs, and the entire floor is stabilized with Martin-Senours' product.
Todd.