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Paint stripper, wire wheels, and lots of elbow grease. I tried a orbital sander with 80 grit pads and it barely touched the CARC.

I'm planning to spray whatever I strip with phosphoric acid to keep the rust at bay. When I get a few parts stripped I'll paint them all with POR-15.

Well I ordered the sandblaster attachment and bought a 3100 psi and 2.5GPM pressure washer at home depot. The attachment should be here tomorrow and I'm going to do a test run when I get home from work. Stand by for pics. EDIT: Looks like i'm going to have to reschedule the pics for tomorrow...

I had no idea this existed! Learn something new every day. The reviews are positive too. I might just skip the compressor rental and buy a pressure washer instead. Here's a thread talking about it http://www.steelsoldiers.com/welding-sand-blasting/4030-pressurewasher-sandblaster-attachment.html

So you blast with all the panels still on the truck? Do you have spots that you can't reach?

Well my rough outline is to remove the bed and all the panels except for the cab itself. Blast everything and paint the frame/axles with por-15. Then do rust repair on the panels and por-15 those when done. I figure a little surface rust won't hurt too much since por-15 requires treating...

Is that just for the frame or the body panels/bed too? Did you reuse the sand? The combo you used would cost me $130ish per day + media. Might be worth it if I don't have to touch paint stripper again.

There is a place around here that can rent me a 180CFM diesel air compressor for $60/day. I'm thinking about renting it for a weekend, hooking it up to a HF 110lb sandblaster, and stripping down my truck. I'd use Black Diamond media from TSC. My question is will something with that much juice...