Looking to repaint my Sahara somewhat economically (~$3K or less?).
First question - why should I use the modern approach of color/clear coating? Sahara paint is not necessarily one of those that has a deep luster, its kinda shiney-flat, or flat-shiney. Wouldn't the old fashioned solid color paint job look pretty good? Or does it have to do with the availability of modern paints? It also seems like clear coating is more prone to later peeling and clouding, and more difficult to DIY small repair areas.

Paint type - Is enamel original? Is enamel available today, or is urethane the standard?

What primer type? My car would have a lot of paint removal to metal, but not necessarily 100%

Finally, how do you deal with all of those places with nooks and crannies that have some surface rust at the joints, or where sheet metal has been folded over? like under the hood and trunk edges? Is there primers or treatments that can seep in there to seal the rust?

Looking to be armed with good questions and knowledge for the shops I might visit.

Thanks for any knowldge.
Mike

With "modern" paints, the clear over color (or color & clear mixed in the final coat) would add a nice gloss to the Sahara (my original '02 was a Sahara '70).
You need to ask the shop who will be doing the work what THEY think about the choices & possibilities - they're experienced and will have recommendations.
Nooks & crannies with surface rust need to be addressed, or you'll be having it all done again, sooner than later!

I initially had the same thought as you but if you are going to spend anywhere near $3k, might as well get the clear for the extra protection. If you plan on keeping it awhile and eventually end up polishing if for one reason or another(bird doo, sap, train rail rust, oxidation, etc) it's nice to know that your polishing pad won't be colored the same as your car after you get through. :)

Another benefit of clear(I recommend at least 2 coats) is if there are any imperfections or there is more orange peel than you'd like, you can wet sand and buff it to a mirror finish. Most beginners or cheap places tend to exhibit more orange peel than others.

As for rust in nooks and crannies, I have those too and plan on sanding it down where I can and applying POR 15 to prevent the spread.

Clear coar is for UV protectiona and to provide a shine to the base coat(your paint color.)

Enamels are still in use, as we use urethane enamels.

For a nice primer, make sure they use a euroxy(urethan-epoxy) primer(it seals, primers, surfaces and has corrosion protection.) Best option for restoring cars but it is pricey.

Sand paper and elbow grease, knock the rust out!