ELECTROLYTIC RUST REMOVAL

A USEFUL AID FOR REHABBING HAND TOOLS

Rusted Hand Plane BEFORE

Electrolytic Rust Removal

P O L A R I T Y

Rusted Hand Plane AFTER

Electrolytic Rust Removal

I S

C R I T I C A L !

The BLACK (negative) lead is connected to the part being cleaned

The RED (positive) lead is connected to the rebar anode grid

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SAFETY CONSIDERATIONS
1. Before starting, review the Material Data Safety Sheets (MSDS) for the recommended products
2. Use common sense if it doesnt feel right dont do it!
3. The gases generated are oxygen & hydrogen
4. Do this process in a well-ventilated area away from sparks or open flame
5. Wear gloves and safety goggles / glasses
6. The electrolyte solution is mildly alkaline and could irritate your skin and eyes
7. Wash any sprayed electrolytic solution off your skin with plenty of fresh water
8. Despite some recommendations, DO NOT use stainless steel for the electrodes as the results produce a
toxic solution containing hexavalent chromate. Hexavalent chromate is a poisonous and hazardous
material that requires special handling and disposal.
9. Click here for a good discussion of why NOT to use stainless steel

MATERIAL SAFETY DATA SHEETS

1. Washing Soda MSDS
2. Glycolic Acid MSDS
3. Kaboom MSDS

MATERIALS LIST
1. 5 gal plastic bucket
2. inch x 18 inch rebar pins for anode grid
3. copper wire
4. wire nuts
5. large alligator clips
6. Arm & Hammer Washing Soda (sodium carbonate)
7. 6 amp 6/12 volt battery charger
8. brass brush
9. 3M grey abrasive pad
10. WD-40
11. BoeShield T-9

BUCKET PREPARATION
1. Drill holes near edge for twisted wire loops
2. Secure rebar with twisted wire
3. Connect rebar anode grid with copper wire & wire nuts

After electrolytic rust removal, use a brass brush and a 3M grey abrasive pad for final cleaning.
Residual stubborn stains are easily removed with a bath in a mild citric acid cleaner, or
alternatively glycolic acid such as Kaboom Shower, Tub & Tile Cleaner.
After the acid bath, rinse parts in fresh water and run them in the electrolytic solution for
15 minutes to neutralize the acid. Then rinse in plain water.
After completing the de-rusting and cleaning process treat all parts with BoeShield T-9 or
alternatively WD-40.

CLICKABLE ONLINE RESOURCES

1. Instructables Rust Removal
2. Electrolytic DeRusting
3. Barrys Woodworking Rust Removal
4. Electrolysis Rust Removal
5. Geoffs Science Garage on YouTube

Twisted wire and wire nut securing rebar

View inside bucket of rebar secured to

to wall of 5-gal plastic bucket

bucket wall with twisted wire

View of rebar anode & copper

cathode wires
View of the plane iron & chipper hanging
in electrolyte solution suspended by
copper wire

Refurbished plane iron and chipper

compared to rusted plane body

Close-up of rusted plane iron ready

to be cleaned

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