Electrolytic Rust Removal aka Magic

 by ToolNut
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Step 2: Assemble tank and anodes

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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HasBeen says: Feb 3, 2013. 11:09 PM
Nylon zip ties will hold your rebar securely, but you will still need copper wire around the rebar for the electrical connection. Also bend the copper wire so wire nuts point with open side down so they won't fill with any splashed solution and rust out quickly.
Ian.Harrold says: May 9, 2011. 12:26 PM
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.
ToolNut (author) in reply to Ian.HarroldJan 12, 2012. 8:37 PM
Hey Ian -Sorry for the massive delay in responding (kids!) - I dont think it was a super well thought out aspect of the design. I don't I agree with corey11 (see my response below) that it would be catastrophic - but any system you design you need to be comfortable with the safety etc etc. I didnt worry about even electron flow because I dont think its enough current to run into resistance issues by having to go further around the bucket, and honestly it was one less connection I had to wire together! Though it does mean that if you have a bad connection at the rebar (or eventual rusting out of wire) then the whole line goes out rather than just half.
bongodrummer in reply to Ian.HarroldMay 20, 2011. 4:07 AM
I am intrigued and wondering the same thing?? Why not ToolNut?
corey11 in reply to bongodrummerOct 25, 2011. 8:20 PM
because it could short circuit the (anode? or cathode?) the negative terminal by completing the circuit therefore welding everything to itself. Bad idea.
ToolNut (author) in reply to corey11Jan 12, 2012. 8:33 PM
Really?? I cant figure that one out - it would basically be a loop on the end of a negative circuit -its not touching back to the positive - just the negatives all connecting together... Basically a big version of the little loop on the negative terminal of your car battery as far as I can tell... Or am I missing something?
rlm98253 says: May 15, 2011. 11:08 AM
"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.
ToolNut (author) in reply to rlm98253Jan 12, 2012. 8:25 PM
I'm going to build v2.0 this winter and try that... Thanks.
Kelth says: Jun 9, 2009. 6:45 PM
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....
michael1960 says: Jun 2, 2009. 11:48 AM
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.
ToolNut (author) in reply to michael1960Jun 5, 2009. 7:36 AM
yep - thanks - just fixed that. Home depot etc has rolls of tie wire too - very handy for all sorts of repairs. one step in strength below baling wire.
sos22 says: Jun 1, 2009. 3:47 PM
What is "tire wire" and where do you buy it? I've never heard of it.
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