I have been experimenting with rust removal using electrolysis. There is a lot of info about it on t'internet but I am always suspicious of magic solutions to rust removal so I thought I would try it. Amazingly it works!
I used a large food container with some re-bar as the anodes and a weak solution of Sodium Carbonate. I already hace a handy 12 volt supply in my "man shed" so that bit was easy. I adjusted the current flow to about 1 amp with a couple of resistors. Not sure if that is right or not but seems to work. I guess it depends on the size of the piece you are de-rusting.
witches_brew by
Robin Martin, on Flickr
And the proof of the puddding (or before and after....)
before_after by
Robin Martin, on Flickr
It seems to be a great process. Removes the rust without removing any underlying metal. And far lesss messy than a wire brush in an electric drill. If you try this though, the process generates hydrogen, so it must be done in an area with good ventilation or preferably outdoors.
Now all I have to do is the 100's of other parts...
Cheers, Robin