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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