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I've done this same thing on many pick up and larger truck frames and i agree that the needle gun is the key to the larger scale. My perfered method for final clean up is knotted wire brushes on a angle gringer. They have the grit to remove the hard rust but can get into all the little pits...

An easy route for the engine oil cooler would be to order a Heath Blue Ribbon oil cooler for a 6.5l and make mounts on the core support. They send all there kits with both style fittings for 6.2/Early 6.5 and older 6.5. As far a a trans cooler, I have a 1008 for a plow truck and i mounted a...