will this work on a primed surface that has no rust?

Not true on the "won't help" besides neutralizing rust. The product contains zinc which will adhere to the metal surface and prevent rust. I sand blasted my brush guard, primed with rust binding primer and painted. Rusted in several months. Did the same thing but used this product before painting and 4 years later - no rust.

How do you apply this? Spray bottle or brush?

You use a brush..and you must keep the surface wet for at least 10 minutes...or up to 30 if depending on severity of the rust in the area you are treating. This is what 'kills the rust' So dont do too large an area at one time. After 10-30 mins of keeping the area wet with this..you hose off thoroughly and let dry COMPLETELY. (use a fan if necessary..but make sure corners and all crevasis's are completely dry or por 15 wont adhere there.Do not be in a hurry! Once its completely dry...apply the por 15 and your time and effort will be rewarded.

dose this get down in the creases of metal

If you put it on thick it will flow while it is wet. Depends on the size of the gap. It will probably bridge metal that is like the crease of a metal funnel. Hope this helps

Could this be mixed down with water to allow it to be sprayed?

HI Robert. Are you asking about Metal Prep PQR-15? It is mixed down into a solution that is ready to spray. I would not dilute it any at all, in my opinion this stuff is way too weak and were you to dilute it further, well you might as well use Kool Aide as it would work just as well. Now I did respond to this product by saying that I am now using a food grade of Phosphoric Acid that's at an 85% concentration. The operative ingredient in most of the good rust removers / converters whatever you like to call them, is phosphoric acid. Using the 85% grade concentration it HAS to be diluted! I would suggest using an old Windex or 409 bottle to mix this stuff up in and spray it. The trigger sprayers you find in the hardware stores are junk and won't stand up to high or low PH solutions. So if you decided to buy some of this "high test" phosphoric acid I'd mix it down like three or four ounces to 400 or 500 ml of water. Pour the Acid into the water! Not the other way around! You can buy this acid off of Amazon by the way. Be careful with it, use a respirator rated for organic mists and vapors when using it, and of course wear gloves and eye protection as well. I hope this helps?

Brand	POR-15
Color	multi-color
Finish Type	Metallic
Size	32 Fl Oz (Pack of 1)
Item Volume	1 Quarts
Special Feature	Non Flammable
Unit Count	32.0 Fluid Ounces
Paint Type	Oil, Spray, Watercolor
Specific Uses For Product	Exterior
Surface Recommendation	Metal
Indoor/Outdoor Usage	Outdoor
Item Form	Liquid
Included Components	1 container
Is Waterproof	False
Model Name	40204
Package Information	Can
Coverage	2.5-3 sq ft/quart
Water Resistance Level	Water Resistant
UPC	051491402040
Global Trade Identification Number	00051491402040
Manufacturer	POR-15
Item Weight	2 pounds
Product Dimensions	12 x 8 x 6 inches
Item model number	40204
Is Discontinued By Manufacturer	No
Exterior	Zinc
Manufacturer Part Number	40204
OEM Part Number	40204
Special Features	Non Flammable

Metal Prep, Metal Etching Rust Neutralizer, Non-flammable and Water-based, 32 Fluid Ounces, 1-quart

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