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Electrolytic Rust Removal aka Magic

Step 2Assemble tank and anodes

Assemble tank and anodes
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NOTE: Do not use stainless steel for the electrodes. As pointed out by a commenter on the intro page (thanks!) "The chrome in the stainless will leach out during the electrolysis and form hexavalent chromium compounds in your electrolyte. These are extremely bad for you." This is true - dont even think about using stainless steel for this project.

Assemble tank and electrodes

1) Space the rebar evenly around the bucket along the sides (running top to bottom). Mark the locations

2) Drill two small holes about 1/2 inch apart 2 down from rim for each rebar

3) Insert a 5" loop of tie wire through the holes around the rebar and out again . Lube the ends of the bar with anti oxidant compound and twist the wire tight and snip off so 1" of the wire is remaining. UPDATE: the tie wire eventually rusts out - mine in less than a year.  Consider using something more resistant to rust - suggestions welcome.  On the other hand, any time you are using electrodes, they are sacrificial - as is the wiring system that contacts the water, etc.

4) Once all rebar is in place, make 4 sections of copper wire with the ends skinned off to connect each rebar wire.

5) Wire nut each rebar to the next with a section of cooper wire (connecting the protruding tire wire (I also used Noalox on these connections). Do not connect the first and last rebar (ie: X---X---X---X---X---)

6) Add 5 tablespoons of washing soda to the bucket and fill within 2 of the rim with clean water (adding extra soda will not help&)
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6 comments
May 9, 2011. 12:26 PMIan.Harrold says:
So why did you not connect the first to the last rebar? Electrically it is already connected, but I would think you would want provide even electron flow by tieing them together.
May 20, 2011. 4:07 AMbongodrummer says:
I am intrigued and wondering the same thing?? Why not ToolNut?
Oct 25, 2011. 8:20 PMcorey11 says:
because it could short circuit the (anode? or cathode?) the negative terminal by completing the circuit therefore welding everything to itself. Bad idea.
May 15, 2011. 11:08 AMrlm98253 says:
"UPDATE: the tie wire eventually rusts out - mine in less than a year. Consider using something more resistant to rust - suggestions welcome."

Bare 12 gauge copper wire is excellent to secure the rebar for this project.
Jun 9, 2009. 6:45 PMKelth says:
The part I want to clean is a small stainless steel blade (straight razor) Can I use this even though its stainless steel? or no? it is small....
Jun 2, 2009. 11:48 AMmichael1960 says:
It's a typo. I believe he means "tie wire", used to tie rebar together. It can be found in ranch and farm supply stores.
Jun 1, 2009. 3:47 PMsos22 says:
What is "tire wire" and where do you buy it? I've never heard of it.

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