Well im sure all of you have heard of this before, but i didnt until my grand dad told me about it and i just HAD to try it out, i thought you guys could all use it
Rust Removal via Electrolysis

Pretty Simple idea to it all
fill a tub with water, add 1 table spoon of washing per gallons (baking soda works too)
Make a basket that is conductive, and strong enough to hold parts
find some Rusted things you want clean
find some junk metal you can live without, rusted or non rusted, as long as it CAN rust
hook a battery charger to it and you have yourself a chemical reaction that separates iron oxide from metal
i dont have any pictures of my own results but i drew this up if anyone is anxious to try it



my basket was a shopping basket wrapped with uncoated copper wire all over it.
a 2x4 to support the basket,
and attached the wire around the basket to the NEGATIVE LEAD of the battery charger
and had an old metal wire rack i put at the bottom attached to the POSIT?IVE LEAD
turned it on and overnight the water turned bright orange and my exhaust manifolds look brand new, the metal rack , was destroyed, this is why you must hook it up with proper polarity


here is a picture similar to my results



also with the proper set up im sure you could do a whole shell or chassis, as it takes away NONE of the base metal only the iron oxide

 

I met a guy on the internet, he was actually a member here but I haven't seen him on in a long time, that built one of these and it worked perfectly. Good job!

 

Keep in mind, you need to do this in a well-ventilated area. Electrolysis also converts H2O into hydrogen and oxygen, which makes for a rather explosive mixture.

 

the amount of hydrogen produced is minuscule compared to what it takes for an actual explosion of any kind, unless you do it in a sealed bubble or something

 

Like I said, well ventilated area:P I just wouldn't put it in a box or small closet. A corner of the garage is fine.

 

+1 Starfury is correct.

H2 and O2 can be quite combustible! Be very careful!!! Make sure to examine the chemicals being added to the mix.

 

damn... now I have a new project

 

relativley simple
BUT..... it takes it down to 100% pure iron or steel suface, in water
which you have to dry off IMMEDIATLEY, then spray with wd40 or like water deterent

my manifolds look just like they did now.

 

If I had read this two years ago. That is sweet man. I will still have to try it.

 

It also removes any crud and paint. I used a battery charger and it did a great job on lower control arms that were all gunked up.
You do need to use a brush on them during the process. Works well.