I read the thread on Sylvan's vise plight and there was mention of electrolysis, so I found out what it was (DAGS, thanks) and put my evil plan into action. To make sure I didn't mess up anything important, I used an old lawn mower blade (negative lead) and a piece of reinforcing steel. Hooked up the ol' battery charger on 2 amps and let 'er run for a few hours.
Holy cow! It's magic! Some kind of voodoo went on in that bucket and now I have a lawnmower blade that's (half) perfectly rust free! I was so impressed with the results that I sprayed a little WD40 on the clean half and brought it with me to work to show all my coworkers this Amazing Electrochemical Process!
I'm sorry to say, they weren't impressed by a half-rusty lawnmower blade. I explained to them that this is totally non-abrasive, doesn't remove any extra material, and is potentially explosive. Nothing. Not even the Zero-Elbow-Grease argument brought them around.
However, my enthusiasm is undampened. Next is a pipe wrench. Then, a hand plane (Stanley smallish jack plane--a cheapo, I'm sure) so that I can try *again* to sharpen and tune one. Hell, I even called up my Paw In Law and asked him if he had any rusty tools he needed electrolyzed.
Perhaps this is less amazing than I am giving it credit for. But after a lifetime of wire brushes, steel wool and naval jelly that didn't work, I am totally impressed.
Okay, I've taken my Ritalin and I'm ba-ba-back to normal.
-Phil Crow