Electrolysis Rust Removal - Motorbike Fuel Tank





Introduction: Electrolysis Rust Removal - Motorbike Fuel Tank

So have you just found a layer of nasty rust on the inside of your fuel tank? well we may be able to help!!
Electrolysis rust removal is easy but takes a some time.
you need;
-one 12v battery charger
-soda crystals
-strip of mild steel

Step 1: Preparing the Tank

Firstly clean out the tank of fuel, remembering to dispose of waste fuel safely!!
Don,t worry about washing it out just shake out any loose bits if you can.
we will doing the tank in two parts, with the tank in its normal position and then upside down. both are done exactly the same way.
This instructable will show the upside down part, but right side up is the same method.
Do this in a well ventilated area, prefably outside as the process of electrolysis will produce hydrogen gas!!
Make sure the tank is stable and block any pipes coming out to prevent leaking.

Make sure the cap seals properly, if in dought use some plastic to help it

Remove the fuel level sender

Step 2:

insulate the end of your steel electrode. i am using some 12mm square bar i had lying around. only mild steel will work, so no stainless or alloy.
place the eletrode in the tank trough the hole and mark where it sits against the tank. insulate that part of the electrode, i used some rubber tubing.
it is important that the electrode does not touch the tank or it will short out the power supply.
wiggle it around and make sure that it is not touching any metal pipes inside the tank.
it should rest on the bottom on its insulator and the hole at the top.

Step 3: Filling It Up

mix 1 table spoon of the soda crystals to 1 litre of water.
fill it up to the top

Step 4:

put the electrode back in and make sure its not touching the tank.
connect the positive clip (RED +) to the electrode
connect the negative clip (BLACK -) to the tank body

make sure to get them the correct way round!!

Step 5: Switch on and Wait....................

turn on the power and wait. it will start fizzing away and bubbling. this will continue and eventually the water solution will turn really gunky as the rust is lifted of the metal. a lot will stick to the electrode.
if the tank is really bad take out the electrode every 6 hours or so and wipe it of. turning of the power first.
some solution will bubble over so make sure it can drain away.
the longer you leave it the better the result. anything from 24 hours to a week.

Step 6: Rinse and Dry

when done rinse out the tank with water and dry thouroly. put it by a heater to help it along!!
when dry shake it around to remove any residual flakes and your done.



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    Did you have to treat and seal the tank afterwards, and is so what did you use?

    Just trying this out on a rusty Honda Revere tank, seems to be working OK :)

    i hope the power supply won't blow off, because it's being short circuited if we don't use any resistant, a light bulb or so.

    I have tried the above method to clean my tank and the charger is working however when inserted in the tank it is not showing a light to indicate it is charging - any suggestions ?

    Instead of water to rinse, you should use rubbing alcohol. It evaporates at room temperature so it has a smaller chance of contaminating your gas and you can use the tank sooner than waiting for water to evaporate.

    Great post. Going to try this. Should I oxy clean out all the crystallized black old gas first? Or can I go straight to this you think?

    what setting do I use 12v or 24v, 2amp 20amp 50amp??

    Soda crystals are just sodium carbonate. A cheap source for sodium carbonate is the stuff pool supply stores sell for increasing Ph.

    might help if you used an air compressor to blow out any loose particles in the tank. just remember to wear eye protection. if you thought rust in your gas tank was horrible, try it in your eyes;) lol

    Interesting. I've used electrolysis to create rust, but never to remove it. Good to know.