Looking for some advice for the best undercoating to use on frame and suspension/differentials /axles. What have others used and had good luck with? I plan on some wire brush time and want a durable paint or coating. Thanks for your thoughts.
Here's my experience so far living in salt riddled New England and a first gen Tacoma.
If you have access to a compressor, buy a cheap harbor freight sandblaster/soda blaster with a local feed system at the gun and clean up areas desired. Media blaster steel will give you the best results for adhesion when using something like POR or Chassis saver. Personally, go for chassis saver, a lot less proprietary prep and pre cleaners and cheaper. Epoxy like finish when it cures. Don't use it any place that sees sunlight because it's not UV stabilized and will chalk and crack.
If you have to wirebrush then clear rust off affected area and then use a red scotch pad to "blend" the bare metal into the nearby factory finish. Then clean, and clean, and clean. And curse yourself for not media blasting and clean some more. Then apply chassis coating as before.
Let the paint cure sufficiently and then powerwash your chassis. Then grab a gallon kit of fluid film from Napa or amazon (also sells a super cheap gun with flex wand) and find a pancake compressor, find some clothes you don't care about and a hat and start buttering that frame and components. Use a lot of it. Appreciate the smell of it now because room temp it smells pretty good, until the exhaust starts burning off the over spray when you start driving then you'll realize that smell is going to be in your nose for weeks. Use the wand to hit the frame internals. Use a brush when needed. Admire your handywork. Drive around collecting neighborhood dirt onto your sticky oily frame. Every few weeks rinse the undercarriage off with cold non pressurized water out of a hose or a gardening wand.
Last thing I'll mention, there will never be another repair you perform on your car that will involve you crawling under that won't end with you ruining clothing or getting absolutely filthy. It's worth it though, exhaust guy told me last winter that he's never seen a Tacoma with a frame that clean before.