Rust Removal using Electrolysis on a large scale

Click on a thumbnail picture below to get a better view.

Construction of plywood frame to form "tank".

Another view of plywood frame showing trailer frame suspended by rope.

Tank lined with blankets to protect the plastic lining that will be put in.

"Tank" lined with two layers of 32' wide 6mil poly.

Filling the tank.

1600 gallons later.......

1/2" rebar electrode arrays. Rebar is cut and stapled to 2x4 runners.

Arrays in place. Note wires connecting all the electrodes together.

12 hours into the process - Is it soup yet?

After skimming the crud off the top of the water, this is what is looks like.

36 hours later, it's almost finished!

The de-rusted frame loaded up for transport.

Plywood tank walls are about 30" tall. Supports start 14" down from top. The tank "springs" to help reduce damage from bumps.
A DC welder (+) was connected to electrode grid, the (-) connected to the trailer frame. The welder was set to the lowest setting, allowing a 100% duty cycle. (up to 80 volts dc at up to 125 amps)
Cleaning process for the trailer frame took about 56 hours total and about 80 feet of rebar.
Special thanks to Terry Lingle for the photos. Terry has also cleaned up a metal lathe using electrolysis, proving that this process is limited only by your imagination (and perhaps your wife's patience and your water bill)

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Last Updated on January, 2006 by Email: