- To clean rusted metal parts using the electrolytic method, you will need some type of plastic container such as a 5-gallon pail, plastic tub, or plastic drum. You will also need some steel to use as the sacrificial electrodes, some copper wire, a battery charger, water and washing soda. You will also need something to use as a support for your part and the sacrificial electrodes. A piece of wood, such as a dowel or old broom handle, works well with small setups.
- Your part will be suspended in a conductive solution of water and washing soda. Make the solution by adding 1/3 to 1/2 cup of washing soda to 5 gallons of water. There is no benefit to a stronger solution, so don't waste money and make one.
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Prepare four sacrificial electrodes a few inches taller than your container. Concrete reinforcement rods (rebar) works well for these electrodes. Place all four electrodes vertically in the plastic tub, 90 degrees apart. Connect them together using copper wire such that electricity applied to one of them travels to the other three also. Connect the positive clamp of the battery charger to one of these rods.
Hang your part from the wooden dowel, allowing it to hang into the solution. Attach the negative clamp from the charger to the part. If it is small enough, the part should be totally submerged. If the part is too large to allow it all to be submerged in the solution at one time, it is fine to do one section at a time. - Turn on the battery charger and watch for tiny bubbles coming off of the rusted part. These bubbles prove that current is flowing and rust removal is taking place. Allow the current to flow for several hours, or overnight. It will not hurt the part to leave it in the solution for an extended period.
- After electrolytic rust removal, there may be a thin layer of crud left on the part. Use a wire brush to clean this off the part and rinse completely. Dry the part quickly to prevent re-rusting of the part.
- Potentially hazardous situations are created during this process, so be aware of them. Remember, water and electricity can kill. Always shut off the battery charger before handling a submerged part or sacrificial rod. Always have the container outdoors when parts are being de-rusted. Very explosive hydrogen gas is released during this process, so do not do this process in an enclosed area.
