best tool for cutting rust out
 

What would the best way to cut the inner rocker out? cutting wheel, cutting torch, plasma cutter?Any help is greatly appreciated

I always use a combonation of tools,- cut off wheels, small air sawsall, air hammer with various tips, spot weld cutter, and very seldom a cutting torch. I do a rough cut and then come back for fine cuts to the dimension I need. Check out the pelican tech pages to get an idea of what is inside so you don't cut through braces or gussets.

Plasma cutter might help alot, but I am still waiting to get my hands on one so no experiences with one as of yet.

There is a drill bit made by 3m called "paint and rust stripper", it looks like a hardened brown or black sponge and it works wekk to gring off rust and leave the good metal.
It also works good to remove undercoating, paint, bondo and probably more.
It can be found at walmart and probably your local autoparts store.

I have been using it to remove surface rust wher the paint was stripped on my 57 356 it doesnt damage or sand the metal but it leaves "swirl" marks that may need to be sanded for a perfect finish.
BTW
dont bother using a cordless drill use a corded drill.
Regards,
Kelly