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Re: I've searched rust to death, need experienced opinion
Rust forms when moisture, oxygen, and steel get together. If your rusty surface is dry it is possible to use a paint to seal it. Epoxy primer is a good choice because it seals out both moisture and oxygen. But the primer should not be left exposed.
I tend to use acid in spots like you're showing. Muriatic acid is a high strength form of hydrochloric acid and it will react with the bare steel and the rust. It's strong stuff and you need to understand and follow safety precautions. Phosphoric acid is slightly milder and will conver rust into a different form of iron oxide which does not rust. It's a main ingredient in "rust converter" type products but you may be able to find it in pure form. Again, use safety precautions.
After using acids you can rinse heavily with cold water or you can try to use a baking soda solution to neutralize. Most of the time I just rinse. Baking soda often leaves a green or rust colored residue that should be removed before painting.
The final step is to dry the area. Any steel exposed to acid will try to rust ASAP when the acid is gone. Using an air gun to blow rinse water off will cause a tiny amount of surface rust to form but I've never had an issue with it.
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