Rust Removal

[Scott Hildenbrand]

What is the best method of rust removal for large tools and otherwise unsoakable items?

From light rust to heavy with some pitting..

Opinions?

Then what is the best product to use as a protective afterward?

[Cliff Rohrabacher]

You can soak a terry cloth in solution of water an plain old Baking Soda (yah that works) or washing soda (the conventional solution) and do electrolysis with a battery charger.

Just lay the cloth on the metal surface and connect the charger to the cloth and the metal.

You can do the same with a Citric acid solution or Evaporust and no electricity.

Place a plastic sheet on the cloth to prevent evaporation

[David Christopher]

Scott, this is the best stuff Ive ever used

http://www.boeshield.com/rust_remover/rust_free.php

[Nate Carey]

...also to be considered...
http://www.loctiteproducts.com/common/graphics/products/loctite/productshots/01-80276.gif

[Mike Heidrick]

I also use rust free. Buy mine from sears in the two pack (with a spray can of T-9 protectant).

I change it to a fine mist spry bottle though as the pump leaves drips that can etch the surface somewhat. Recently I have also used it with BKF (Bar Keepers Friend - located next to the comet at your local grocery store) and a green scratch pad and then clean all that up with WD-40 followed by Johnsons paste wax. Works awesome.

[Chris Tsutsui]

There was a thread on here a while back with somebody using bar keepers friend mixed with a goo gone type of lubricant. He said it worked great.

If you ask a mechanic, they might say the naval jelly rust remover. I've used rust removers and they work "ok", but requires elbow grease.

For a really badly rusted jointer, I used rust remover jelly as the first stage. Then wet sanded with WD-40 and a fine grit sand paper on block. haha, That got every bit of rust off and the wd-40 protects it from more rust.

[Don Jarvie]

100 grit on a sander then 220. The rust just pored off.

The use a wire wheel.

[Bob Aquino]

I have been using something a wee bit stronger than your typical rust remover. There is a product made for removing barnacles and general cleaning of fiberglass boat hulls called MaryKate On & Off Hull Cleaner.

It is a mixture of oxalic and phosphoric acid. Very nasty stuff, but it will liquefy rust like nobodies business and will not react with non oxidized iron. I put it on with a chip brush and use coarse steel wool to rub out the metal. You have to wear long rubber gloves and have some face protection as well as old clothes or an apron, but you will be amazed at how quickly it removes all the rust on old machinery. I have used it on jointer tables, a large 20" bandsaw table and the top and tables to a 12" saw. Pics tell a 1000 words.
Bandsaw table before and after:
http://lh4.ggpht.com/_nh7rpc89jO0/SLCHY8F87ZI/AAAAAAAADVc/MFUwsookfL4/s800/P1030221.JPG http://lh6.ggpht.com/_nh7rpc89jO0/SLCHigM7THI/AAAAAAAADXg/rqJC-lO93gY/s800/P1030223.JPGhttp://lh3.ggpht.com/_nh7rpc89jO0/SMxQNdqttKI/AAAAAAAAERI/fJ6tMv8fJSI/s800/P1030342.JPG

Table saw top before and after:
http://lh6.ggpht.com/_nh7rpc89jO0/STnVJACQ7AI/AAAAAAAAEtM/675F0xlM25U/s800/IMAGE_224.jpg
http://lh4.ggpht.com/_nh7rpc89jO0/SWp6z2N-_xI/AAAAAAAAGIM/2AWBpc6mqgc/s800/P1030700.JPG

[ian maybury]

Phosphoric acid based rust removers will convert rust to a form that brushes off easily, with the added advantage that the result conversion of the surface to iron phosphate leaves a rust resistant coating.

Another option which i've not used but sound very promising and which claims to bring back bright metal is electrolytic derusting. http://www.stovebolt.com/techtips/rust/electrolytic_derusting.htm

It seems not too hard to set up on a DIY basis, and a check would probably be wise to ensure that it works ok with cast iron but its listed as widely used in tool restoration....

[Jason Hanko]

Another vote for WD40 and fine grit sandpaper. I used my crappy Harbor Freight ROS with 120, followed by 220.
Ive heard WD40 just removes the rust tho and doesnt actually do much to protect metal from new rust. I always go with a good coat of Boeshield (the spray lubricant here, not the rust remover) followed by a few coats of paste wax.

[Danny Burns]

I found that this product is thought by many to do a really good job.

http://www.leevalley.com/wood/page.aspx?c=2&p=58771&cat=1,190,43040

[Chaz Alexopoulos]

I found that this product is thought by many to do a really good job.

http://www.leevalley.com/wood/page.aspx?c=2&p=58771&cat=1,190,43040


I read about Evaporust on here and tried it on my TS, which had a few light rust spots. I soaked a towel and laid it on the top for about 10 mins. When I took it off, the rust came right off BUT, now I can see the outline of the supports that are underneath the table. I don't know if this is etching or what. I followed it up with T1 by Boeshield as a protectant.