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Rusted Stuck Seized Parts, Free At Last

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It's rusted on and won't come off. Some reach for a certain stinky penetrating solvent (WD40) but it doesn't really work well for this kind of thing. Here's what does:

Shock and awe (there are no lubricants or solvents in this particular 'ible).

Shock is provided with a hammer. Awe comes from the awesome power of hellfire... or a little propane torch, pick one.

This technique has resurrected many rusty bikes in salty places like Montreal.

Remember to vote for me if you find this knowledge useful. 

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So many people have spoken of their success with various penetrating oils, I can't even keep track of them anymore. Please view the comments at the end.

Some people have kindly spoken in favour of penetrating lubricants as well. Whyteboar, Cross and toad all advise using PB Blaster and letting it soak in repeatedly. mastershake916 is partial "Yield" by Chemsearch and dlaninga1 suggests JB80 metal conditioner. rimar2000 says "You MUST try using liquid phosphating. You can dip the pieces many hours or days into normal liquid phosphating. It does not attack hands or skin."

Also, mastershake916 asked what I wanted the cog for. It was going to go on a Stokemonkey electric bike motor using an adapter but I changed my mind. You see, I'm building a electric/solar/pedal car in an attempt to merge the superb efficiency and light weight of an electric bicycle with some of the features of a car.

Kevanf1 had a neat idea: "...putting the lot into a freezer for 24 hours. Then try heating. But this time you will not have to bring the metal up to red hot and thus not risk changing the crystalline composition of the metal". Someone buy this dude a beer.
 
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Tspherix9 months ago
Nee- Not a boy's name reference?
snotty (author)  Tspherix8 months ago
Is Nee a name? That's neat; what language is it from?

I was thinking of the Knights Who Say Nee: http://youtu.be/zIV4poUZAQo
Tspherix snotty8 months ago
On step 4 - the caption reads 'nee'. Reminded me of "Hanna is not a boy's name" (Online comic) - Hanna uses a Hammer as his weapon of choice, and commonly (emits) a "Gnee" word/sound/phrase when excited. Totally random, just reminded me. Surprisingly Appropriate.

Nice article. Love the Pix and commentary. :)
snotty (author)  Tspherix8 months ago
Well how 'bout that. "Hanna is not a boy's name" looks fun.

I'm glad you like the 'ible.
jbrobertson598 months ago
What I use as a pipe fitter on rusted flanges is kroil oil best I have found next to a torch and a beater
throbscottle9 months ago
You didn't mention impact drivers - gives shock and twist combined together. Wish I had one...
snotty (author)  throbscottle9 months ago
I wish I had one too :)
Quick-tune snotty8 months ago
I have one... but it don't help much with corroded parts - heat is the most successful path, Acetone and gear oil is really good if soaked for a couple of hours.
Also, for the record... WD40 was mainly developed for W(ater) D(ispersal) hence its usefulness in starting damp engines.
titchtheclown9 months ago
For loosening bolts and screws an impact driver is the ticket. I have an old fashioned hammering type one and an electric driver/ drill combo The dedicated impact drivers are better at loosening because the chuck on combo ones like mine loosens off in reverse. Air powered ones are for heavy duty jobs. My theory is that rust is brittle and hitting it with a hammer shatters it. High pressure water, air or spray lube also help to wash the gunk out of the way, as will washing in warm soapy water. I would mention the dishwashing machine but I don't want to get into trouble again.
Kevanf19 months ago
If the parts that are stuck are small enough you could try popping them into a polythene bag and then putting the lot into a freezer for 24 hours. Then try heating. But this time you will not have to bring the metal up to red hot and thus not risk changing the crystalline composition of the metal. Add to that, no indiscriminate banging with a hammer might equal no broken teeth on any cogs ;) Good 'ible' :)
snotty (author)  Kevanf19 months ago
Heeeey, that's a neato idea. Freeze it to un-seize it. Maybe freezing it in a deep freeze and then dunking in boiling water or hot cooking oil would work. Hmmm...
djimdy snotty9 months ago
I just realized that the local Kroger actually sells huge blocks of dry ice for dirt cheap. That's another possibility for running a major temperature differential.
Kevanf1 snotty9 months ago
Got to be worth a try if you have the time before resorting to heavier methods :) After all, it's not going to hurt anything. I'm thinking of the number of times I've slipped because of getting frustrated with a hammer and bashed myself up :(

Take care.

Kevan
uncle frogy9 months ago
I'm leery of too much heat changing the temper of the steel so seldom use it. I have used many different kinds of penetrating oils and by luck found a product called Kroil. to be the best I have ever used a little vibration and some time and the parts become free.
I love retrieving things from the scrap heap
badams29 months ago
The only aerosol can worth having around the shop is Pennzoil Z-4.

I've busted so many rusted parts loose with it, plus it cleans dirty tools like nobody's business!
oilitright9 months ago
I've seen many items damaged with the heat and beat method. There are materials that won't hold up, like Aluminum. That said it does work sometimes. Personally what I reach for is AeroKroil from http://www.kanolabs.com

I use several of their products. You may have to wait 24 hours but it has never failed me.
branman239 months ago
break free clp made by Safariland works really well also
wryce9 months ago
An old technique is the heat it up and melt some candle wax into it. then let it cool.
rimar20009 months ago
You MUST try using liquid phosphating. It converts iron rust into phosphate, making a lot easier to loosen pieces. You can dip the pieces many hours or days into normal liquid phosphating. It does not attack hands or skin.

Eventually, if the parts are TOO rusted, you must use Chlorhydric acid. it is FAR MORE aggresive, you must have a lot of safety measures: gloves, mask, work vest, safety shoes.
snotty (author)  rimar20009 months ago
Thank you! I've never heard of this method before. Could you write an instructable about it for us?
rimar2000 snotty9 months ago
I hate to burst everyone's bubble, but WD40 is junk for this kind of thing. It was never intended for this purpose and barely works. Even antifreeze works better (because of the corrosion inhibitors). But there is so much better stuff out there now. Kroil, PB PartsBuster, Evapo Rust, CLR, the list is almost endless.

That said, there is just no replacement for the "heat it and beat it" method. In the right hands, a cheap welder can work wonders in all kinds of "sticky" situations. Just beware that once a fastener, chain, sprocket, or other heat treated part glows that its properties change and it has to be replaced. I would hate for someone to get injured or killed as the result one of these "repairs". God forbid someone should work on something for someone else and something like that happen.
Yup - you're right - WD-40 actually means "Water Displacing formula 40".... all it was meant to do is to get water out of ignition systems - when they consisted of points and condensers.....

Another spray out there is called ACF-50 - Anti-Corrosion Formula 50.... it about on par with Kroil, so it takes some time when there's lots of rust, and it's tough to find, as it's usually only industrial or aviation use.

I'd actually never thought of using CLR... being an acid, it should work well on rust...
Eromanga nmcrae19 months ago
40th attempt. It took 40 formulas until Norm Larsen got it right. ;-)

(Displacement, BTW).


Cheers,
Yeah, the WD stands for "We Did it"
Thanks for the explanation. My comment was getting too long to include such info.
snotty (author)  The Lightning Stalker9 months ago
Heat it and beat it? Heh heh heh. I've dedicated step two to you 8D
The pupils of my eyes are now a heart shape.
snotty (author)  The Lightning Stalker9 months ago
*blush*
FYI, a 50/50 mix of automatic transmission fluid and acetone is a great penetrating oil. Check it out:

http://www.practicalmachinist.com/vb/general/ot-penetrating-oil-196347/
bpark10009 months ago
Another method when things are bad is to soak the parts in dilute hydrochloric acid (remove grease/oil first to allow acid penetration). This renders the rust soluble. You know it's working if the solution turns immediately brown (a clear brown like tea). Even better (if the parts are small and you have one) is to put them into a sonic cleaner (in a separate steel or glass beaker with the acid). Rinse the parts before resuming the hammer/heat regimen, so you don't have to deal with acid splatter/fumes. When you heat, you should stay below 400 degrees F. Avoid quenching.
Paul039 months ago
As a mechanic for 50 years I can say the ONLY method described that might work is heat. BUT no way in 10^6 years will a candle work. The whole mass will heat up equally and no affect on expansion differential. Fortunately you don't work for me. But you did show some neat meaningless pictures!
rimar2000 Paul039 months ago
Paul, fortunately I don't work for you, because you are prejudging.

Yes, heat expands proportionally ALL PARTS. That means "also holes". It is to say: if you have a 0.001 mm gap between two pieces, such gap will increase too.

GENERALLY heating uniformly all parts, they loose a bit more easily.

I could testify this in front a judge, based on my own experience.
Heating an outer component rapidly may expand it away from an inner part before that heats and expands.

Also, different metals have different rates of expansion for the same temperature rise. This may have some effect in breaking rust between parts of different metals or alloys.
snotty (author)  Paul039 months ago
Well, all I can say is that the candle worked for me for a bicycle crank arm bolt. This is a small part so it seems that the candle flame was enough in this case; something on a car would probably have all its heat pulled away too quickly to be useful. I suppose the parts must have cooled down at a different rate when I removed the candle :)
Wroger-Wroger9 months ago
The act of using differential heating - like roasting the stuck nut, on the cold shaft, with some vigorous and quick spannering, usually beaks the rusted bond between the two.

Or heating up the aluminium engne cases and dropping the cold bearings in...

Or running some lines of HOT weld up the inside of a ball bearing race, to make it shrink, so it can be pulled out.

The COE - the Co-efficients of Expansion.

Hot part, cold part.

Dissimilar metals that have different expansion rates, per degree centigrade.

dlaninga19 months ago
Not to be "that guy" but JB80 is a great "metal conditioner" made by Justice Brothers. If the heat and the banging don't cut it, give it a shot. Pick up two cans, you'll go through the first one the first day. No, I don't work for them.
snotty (author)  dlaninga19 months ago
Thanks for the tip!
brittniepearl9 months ago
best instructable ever.
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