Rust removal and plating - home style!

keynsham1

Active Member
Having got my engine and various transmission parts all over the garage floor at the moment I also have a lot of rusty nuts and washers to deal with. I was always keen on trying rust removal in white vinegar and I have now had a go. I hung half of an exhaust tab washer in plain white vinegar for 24 hours and this is the result!!

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I was impressed. I plan to zinc plate them all once clean. I have done that before with just zinc chloride powder, a lump of zinc, water, a bit of copper wire and an AA battery. It's simple, fun and effective. More pictures when I have done it!

I really plan to de-rust my cast exhaust manifolds and then repaint them. That is the real purpose of all this.... and a bit of lockdown fever of course!!

Interestingly, the vinegar cleans the metal surface so well that rust will start to reform in about an hour!
 
I've repainted my cast iron exhaust manifolds at least three times now. Each time I try out a different brand of ultra high temperature super special silver exhaust paint. Each new product seemingly even more expensive than the last. Nothing lasts more than a few years! Last summer I wire brushed and repainted the whole system front to back whilst the engine was out for my manual transplant. Less then a year later when I next saw the car from underneath I was dismayed to see it had mostly flaked off again. Still, it looked snazzy for the last TÜV (German MOT) just before I moved back to Blighty. Dazzled the inspector sufficiently to distract him from the new third pedal and DIY gearbox crossmember, 'cough', 'wink'.
Interested to see the result of your DIY zinc coating...
 
So my home plating kit is up and running and all for £20! The results are varied as you can see below:

My laboratory.....

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Fizzing bolts.....

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Finished articles...

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The main problem is the surface finish. The bolts were quite pitted as you can see in the picture. Plating brand new metal is easy but rusty pitted nuts and bolts are another story. My vinegar bath got most of the rust off but it is impossible to fully clean them at home so as always the finish depends on the preparation. I am happy with the results though and they are what I expected and any protection is better than none! Is it worth doing? Probably not, but it's fun and a good bit of lockdown escapism!!
 
Is it worth doing? Probably not, but it's fun and a good bit of lockdown escapism!!
:thumb::thumb::thumb::):):) you took the words right out my brain. I support this type of being, my garage is full of it!!

From a point of knowing nothing about plating, regards home rust removal, a frequent warning is to ensuring no vinegar residue remains before plating.
Good luck......
 
With apologies for being an inveterate train spotter, are those are the 'special bolts' for the warm air collector on the right hand exhaust manifold?
 
With apologies for being an inveterate train spotter, are those are the 'special bolts' for the warm air collector on the right hand exhaust manifold?

That is exactly what they are. There are also a few on the other side of the engine to attach a small heat shield which is between the manifold and the brake master cylinder and to attach the top of the dipstick tube.

Before I plate anything, I dip the part in acid (B&Q brick cleaner actually!) and wash in cold water. I use a bath of water with zinc chloride dissolved in it and a lump of zinc for the anode. Apparently, you can use white vinegar instead of water. Actually, there are loads of ways to do this. I just experimented in my shed!!!
 
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