How this works:
Several other sites do a better job of explaining the chemistry of this - but basically you set up a conductive solution and insert some sacrificial anodes. You hang your rusted tool in the solution and attach it to the negative end of the power supply. You attach the positive end to the anode and turn on the power. The current travels through the solution and in the process flakes off the rust - the flaking/softening occurs because of the reaction at the surface of the good steel that pushes the rust off.
See this site
for more info on the chemistry of it all. (now linked to a waybackmachine archive of the site - modern suggestions for this background are welcome).
Step 1: Gather supplies
This project cost me about $40 because I did not have access to a small battery charger. If you have a charger, then most folks with a decent shop full of crap can do it for almost nothing.
- Clean 5 gallon spackle bucket or other plastic container to meet your size needs
- 5 sections of 18” long 1/2” steel rebar ($5 at Home Depot –
buy in longer sections as needed) (DO NOT USE STAINLESS STEEL)
- 5 feet 12 awg (or so) insulated copper wire in two colors
- 5 yellow wire nuts
- several red wire nuts
- 5 feet pliable tie wire (non insulated) SEE UPDATE on Step 2 - the tie wire rusts out after about a year - you may want to use something more substantial or resistant to rusting.
- Box of washing soda NOT baking soda
- Anti-oxidant goo (IE Noalox – This is not necessary
but helps I think.
- Small battery charger or home made power supply ($20-$50 at AutoZone etc) - Its best if the charger
has a 6v option and an internal "trouble" switch that stops charging if something shorts out.
- Variety pack of alligator clips from RadioShack (unless charger comes with decent ones…)
- Outside outlet or extension cord
- GFCI protected outlet (this is a must in my opinion - working around power and water is stupid unless
you have GFCI protection
- 5 gal water
- misc clamps/small boards
- drill with 1/4 bit
- wire cutting and twisting pliars (linemans tools are best
- wire brush (better if on a grinder or dremel tool)
- anti rust spray or light oil