Introduction
Electrolysis cleans away rust like magic, and you can set up a simple system in your shop with a battery charger and a few household items.Electrolysis? I know, electro… what?
What is electrolysis?
In very basic terms, electrolysis is a method to remove rust without using chemicals. By creating electrolysis, we are using a positive electric charge (anodes) flowing through a sacrificial piece of steel — I recommend using rebar — to pull and attract the rust while simultaneously rejecting the rust through a negative electric charge (cathodes) flowing through the rusty item being cleaned while submerged in a conduit of electrolytes, which is a salt solution made with washing soap and water.
TL;DR: The negative charge rejects the rust (attached to rusty item) and the positive charge pulls the rust (attached to rebar).
The cool thing about removing rust with electrolysis is that it’s self-regulating, which means once the rust is removed it stops working and doesn’t eat away or damage the metal.
As you consider using electrolysis to remove rust, don’t stop at rusty tools. When I realized I could safely revive cast iron kitchen items such as pots, pans, griddles and decorative items like cast-iron shoe molds, my world of electrolysis opened to new options. Not to mention, the price of a rusty cast iron pot or antique tool pan is much less than a pristine one!
Warning: Once you feel safe doing this process it becomes addictive. I found it incredibly satisfying to make something old and beat up look new again!
Safety precautions
Science aside, the most important thing to understand when using this method to remove rust is that basic electrical safety really does matter in this process, and it all comes down to connecting the right charge to the right place and turning on the charger when everything is safe.
Along with the tools and materials listed here, you’ll also need a full face shield, safety glasses, and latex gloves.
Follow the steps to the end before turning on the battery charger. Make the electrolyte solution and then attach all connections (positive charge to rebar and negative charge to the rusty item being cleaned) before you turn on the battery charger. DO NOT turn on the car battery charger until you have completed all set-up steps. You want to avoid water splashing or touching any of the parts once the charger has been turned on and the electrolysis process is underway.
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