I'm a northeastern dweller, so this conversation is naturally coming from a rust-prevention standpoint. Not that the D cars will see salty winter roads, but will see plenty of rain I'm sure.
As the weather warms, I plan on diving back into my S13 project. Last fall I completed the cutting and welding of much new metal to perform a rust delete. As of now the new metal is in, seam sealed, and primed. I'd like to at least coat my wheel wells and forward sections of frame rail with a permanent solution.
I'd like to hold an open discussion regarding products and practices. Body and paint are another language to me, I'm all nuts and bolts. Looking to nail down a reasonable but not counterproductive approach. Things I'd like to address are:
"Undercoat" vs "Bed liner" vs POR-15. What is the go-to? Why?
Brush on vs spray on
Apply over existing undercoating? strip to bare metal? If so, via wire wheel or chemical? Other surface preparation considerations?
Luckily since it's underbody I'm not worried about prep perfection as things like runs, orange peel, etc. aren't overly a concern in comparison to a paint job. I am just overly paranoid about applying a coating that "locks rust in" or allows the chassis to rust from the inside out, as I've heard so much about.
I have no personal experience, but I did find this Juicebox video somewhat informative as far as knowing what the correct procedure would be (skip to 4:30) plus some entertainment value haha