*HOW TO* remove rust by electrolysis

Electrolysis is a cheap and easy way to remove rust

in true blue peter style you will need:

A large plastic container
Some Water
Some Soda crystals
A battery charger
Some scrap new metal
Some wire


Start off with a plastic container - big enough to accomodate the part you want to clean
http://img716.imageshack.us/img716/8742/egtank.jpg

Then line the insides of the tank with metal, the metal needs to be all around the item you want to clean and it needs to be larger in surface area than the item you want to clean
http://img517.imageshack.us/img517/7576/egtankmetal.jpg

Fill the tank with water
http://img687.imageshack.us/img687/8237/egwater.jpg

Add some soda crystals and stir
http://img339.imageshack.us/img339/6615/egsoda.jpg

Wire all the parts you want to clean together - i use mig wire and a pair of lockwire pliers to twist it up
http://img707.imageshack.us/img707/4...wiredparts.jpg

Submerge the bits - taking care not to let the part touch the side of the container
http://img7.imageshack.us/img7/7903/egbeamimmersed.jpg

Connect the sacrificial metal to the +ve and the item you want cleaned to the negative
http://myweb.tiscali.co.uk/hotfusion/rust/diagram.gif

Once its been switched on for a while it will start to bubble
http://img94.imageshack.us/img94/8957/egbeam1hour.jpg

leave for 24-48 hours - longer if necessary

when you remove it - wash it off in water, and then ideally methalyted spirits - then a quick wire brush and you should see some good results


Before:
http://img27.imageshack.us/img27/437...stycaliper.jpg
http://img46.imageshack.us/img46/5459/egrustybeam.jpg

After:
http://img51.imageshack.us/img51/928...percleaned.jpg
http://img697.imageshack.us/img697/1...eamcleaned.jpg

As a note - wear eye protection and gloves as you wont want the soda solution in your eyes!