Remove rust using abrasives.

Little Dog

A2OC Donor
European-Union
Unfortunately sometimes you just have to. I'm not going to mention wire wool, wet and dry, wire brushes, emery cloth nor the angle grinder.

The methods I'm going to cover here are:

Cat litter
Soda blasting
Grit blasting

Got all three to do in the next week, currently shaking the cat litter and taking pictures. More in a little while.
 
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Cat litter, I have cat litter for cleaning up oil spills. Far a joke I put some components in a Tupperware container, put some fresh cat litter on top sealed it and left it somewhere I would pass frequently. Every time I when by I gave the container a shake.

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A good method for prepping components prior to plating. Cat litter does absorb moisture so if there is a slight orange tinge to your components stick it all in the oven for a while and when cooled down start shaking again.
 
Grit blasting, very simple and effective.

These two components are not suitable for electrolytic rust conversion due to having a felt backing. The conversion process would remove the rust, paint and felt. The rust is bubbling under the paint, especially around the edges.

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Get some blasting grit and grit blasting tool. Connect to compressor and turn pressure up:

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Minutes later:

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A small amount of rubbing to do, paint and assemble:

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Never finished this thread, some of the methods I only use occasionally but will be next week.
Comment to push this thread to the top of my thread list so I remember to take pictures.
 
If you have patience and the part is small enough to fit in a bucket you can make-up a solution of diluted molasses.
Yes buy a pack of molasses from the supermarket, dilute with hot water and leave the rusty parts for a couple of weeks. The rust disolves to a slimy coating that you wire brush off.
Just note there is a unique sweet smell in the air!
Lots of vids on YouTube.
 
cat litter!!!

Thats a new one on me. And the molasses bucket.
I know about the electronic anti rusting process.
 
cat litter!!!

Thats a new one on me. And the molasses bucket.
I know about the electronic anti rusting process.
 
Old school rust removal for those of us who have owned pre 1990s cars:

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The focus of today's efforts is a drive shaft. It should really come off and go in molasses but I need this car out of the way so I can progress the A2 engine replacement.

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Scraping with the chisel revealed the extent of rusting:

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The steel is surprisingly hard, reinforcements are required:

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After filing, wire brushing and rubbing with emery cloth:

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It is impossible to get all of the rust so a rust converter is required to complete the rust removal:

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First coat of satin black paint:

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Should last a few years
 
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Old school rust removal teamed with modern 18V:

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The flexible drive and various shaped wire wheels are to get into all of the corners. They won't get everything so emery cloth will be required in the tightest corners. Once you have achieved a dimpled pitted look to the rusted areas the rust is removed as much as it can be by this method:

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Watch out for raised smooth patches, this is rust that has not been dislodged and has been polished by the wheel. I had two that I located with a mirror behind the arch so no pictures. Get a sharp woodworking chisel to them and wire wheel again. At this stage there are still traces of rust in the pitting so degrease and rust convert:

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