Any tips on prepping for using Rustoleum? Also, I don't have a paint gun nor experience using one.
I'd forgotten about Rust Encapsulator. There is another product called Rust Bullet(?). I do know people who've used both products and stated them to be superior to POR-15 in both coverage and ease of application.
I should have mentioned I've used it and not been very happy with the results.
I think that, overall, I'd rather avoid using any type of spray paint from a rattle can. Something applied with a brush would yield better coverage.
A lot of people make the mistake of wiping done their parts with Lacquer thinner of Acrylic Enamel reducer. These products tend to leave a film on the parts, thus not promoting good adhesion.
Once I have prepped the part to the condition I am trying to achieve, I take wax and grease remover and clean the parts. Then believe it or not, I spray Windex on the parts and then flood them with water. Yes water promotes rust, but if you take clean compressed air and remove the water quickly, you will have no more corrosion present than if you left these parts out in the open air for any length of time. Once this is done, I use a Metal prep solution on the parts. This will help dissipate any surface rust that has crep up.
Purchase a good aresol etching primer and apply to your parts. It works on cast iron, steel and aluminum. A light transparent coat will do the job. You're not looking for build, just a film to bite into the surface.
I mentioned dipping the parts for the specific reason of avoiding the use of a spray gun and it has the ability to creep into crevices that some spray applications will not reach.
Wet on wet your application, meaning once the primer has flashed well, dip or spray your parts. When I dip, I use a baking pan about 2" deep. Lay the parts in the pan and poor a sufficient amount of paint into the pan and use a spoon to ladel the paint on areas that are not covered by the paint. Hang the parts and watch them gleem better than they ever did when they were new. Note, you will need to pull the dripping paint off of the end of the part. A paper towel works great for that. Another tip is to take your left over paint and place it in a refrigerator after use. You can get a few more hours out of the product by doing this if you are going to do this over a period of a few hours.
I have used this process for 20 plus years with great results. Good luck