One of the benefits of being to able to work on motorcycles is that you can generally find them pretty cheap when work on them is required. Typically, a bike that needs work has been sitting for a while, usually with the tank empty. This means over time that rust has taken over, as was the case with a 1981 Honda CB650 that I had acquired. To say that this thing had rust in it was an understatement; it had chunks of rust. Luckily though, the tank had no pin hole leaks or anything and was completely solid. Now to the fun part! I will explain the process of removing rust from a motorcycle gas tank. As I stated, this was done on a 81′ CB650, so it’s tailored to that, but I’m sure it’ll work on most other bikes.
What you’ll need:
Distilled water (it’s important that you only use distilled water)
Two stroke oil
A length of chain 4 to 6 feet long
Something to plug the fuel outlet (I used a small piece of hose a small rag and a piece of black tape)
IMPORTANT NOTE: ACETONE AND RUBBER DO NOT MIX! If you use rubber to seal the fuel output replace it every time you drain the acetone mix as the acetone will eat away at it.
At this point I’m going to assume that you have the gas tank off the bike and that it’s empty. Here is a step by step.
Plug the fuel output and make sure it is sealed
Fill the tank about ½ full of acetone and let it sit turning occasionally
Shake the tank and empty the acetone/rust mixture into a bucket
Fill the tank ½ way again with acetone and this time drop the chain in
Shake the tank often and vigorously. The chain will knock remaining rust off
Empty the acetone/rust mixture into the bucket
Fill the tank up with distilled water and empty it out. Do this until only fairly clean water comes out and no rust can be heard rattling around. I put a hairdryer in the fuel hole and dried it out immediately after
Fill the tank about ¼ with two stroke oil and shake it around then empty it
Please dispose of the acetone and other nasty chemicals properly
I highly suggest installing an inline fuel filter on the fuel line in between the tank and carburetor. It will filter out any small particles and keep them out of the fuel system. This system worked for me, my CB650 ran like a dream after cleaning the tank like this! The next step is to give the carb a good cleaning.
I first heard this Sun Tzu quote from my friend and NFL Veteran,
John Welbourn. It REALLY hit home for me as I have experienced
Countless times how an environment can lift you up or hold you back.
Surround yourself with battery chargers as our friend Joe Polish says to gain inspiration from others
As a parent, keep an eye on your kids’ friends. Do they make your child better or add more stress?
Whether it’s work, sports, gym – you’re always in an “environment” and surrounded by people. Make sure these environments are charging your batteries!
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Producer – Marion Abrams, Madmotion, llc.
Host & Show Notes: Zach Even – Esh
Cleaning tools by electrolysis……….In this film I am getting rid of rust on some fine machine tools by putting them into a home made electrolytic bath powered by a battery charger.
This is a very simple set up to do at home, but do take care as both electricity and chemicals can be dangerous – so only do this if you are familiar with this sort of thing, and the potential hazards, including the washing soda!
My set up is very simple, I use a car battery charger and a sacrificial electrode on the positive clip – any old iron rod will do; then on the negative clip I put the piece of rusty metal that I want to clean – this is then put in a plastic bucket filled with water and washing soda. After about 20 minutes the tool should come out fairly clean and a bit of wire brushing will bring it up very well indeed.
In this film I clean up a milling hold down set that I picked up in my local scrap yard and it comes out really well.
With nothing but a battery charger and my girl-power, I solve a thorny rust removal problem.
As you can see, the underside of my rear fender has a lot of surface rust and is very pitted. To remove this rust, I have a few options. I can remove it mechanically, using a wire brush or a sandblaster, however, I would run into a few problems.
First problem: There is a few tight corners where it would be really hard for me to reach all the rust. Two: I might heat the metal to a point where it warps, and Three: I might thin down the metal too much.
I could also remove the rust chemically, however, that also has a few problems. The first problem is that it’s not environmentally friendly to dispose of the wastes. The second problem is that it’s fairly costly. If I were to use the best solution of chemical removal, it would have to be half vinegar, half water. And even for me to fit this fender in that solution, I would need 375 gallons, and that would cost me about $500.00. And also, even that, with removing it, I would kill a lot of fish here in Teddyland. And no teddy bear wants to go without fish for dinner.
So let me ask you. What would Chris Hemsworth do?
[Sound Effect] “Schaaaa-wing!”
Chris Hemsworth would use electrolysis.
For electrolysis, you’re gonna need a few key ingredients. First is, obviously, your rusty piece of metal. Second, a car battery charger. Third, your water tank. Fourth, a sacrificial piece of metal, and this piece of metal needs to be cast iron or steel. No stainless steel, otherwise you’ll introduce chromium to your water tank. And hexavalent chromium is a terrible way to get cancer! Fifth, you’re gonna need a form of electrolyte to make the water more conductive. Normal table salt will do, as well as baking soda or sodium bicarbonate. However, the best to use is sodium carbonate or normal washing soda. You’re gonna need about a tablespoon per gallon, and for my 375 gallon tank I needed about four boxes.
Before I start, I’m gonna use dish soap and water to wash any excess oil off the part.
And now I’m gonna submerge it in the tank.
I’m gonna put my sacrificial anode in to where it has line-of-sight to all the most rusty areas of my part and to where it can’t touch the part. For your electrical connection, you don’t want to use anything other than steel or cast iron because any other metal will introduce ions to the solution that will cause problems. So I am using a steel coat hanger instead of a copper wire to connect my piece.
I’ve hooked my positive lead from my car battery charger to my sacrificial anode, then my negative to my car part. Once the electricity starts flowing through this, it’s gonna create two different reactions. The first reaction is when the water molecules’ hydrogen and oxygen are gonna be breaking apart. The hydrogen is gonna be bubbling off of the cathode, then the oxygen is gonna be bubbling off of the anode. Now children, don’t do this in your basement because the hydrogen will also go into the air, and hydrogen is a very flammable gas. And, it is a terrible way to blow off all your limbs! Now, the second reaction is the most important, and the reason we are doing this.
This rust, or ferric oxide, or Fe2O3 is an unstable compound. And so once the electricity starts flowing through this, it’ll become magnetite, or Fe3O4, and become a stable compound.
If you look really carefully along the edge, you can see the bubbling of the hydrogen coming off the cathode. You can also see the oxygen coming off the anode.
It’s been about 5 and a half hours, and as you can see, the water’s nice and foggy with pieces of paint and rust that have flaked off. And the corner of the piece itself has some black where the magnetite has replaced the rust and where the rust is falling off.
Once I got the fender cleaned up, I could still see a tiny bit of rust in the deep pits, so I put it back in to cook overnight.
Here’s a before-and-after of a piece that I have finished and then a piece that I haven’t. These two rear fenders were in roughly the same condition before I started, so you can see that the electrolysis worked really well. I had to use an older car battery charger because the newer one wouldn’t let me run any amps through it unless there was an actual battery connected to it.
I ran my car battery charger at 100 amps, and realistically, it was nearly done at five and a half hours. So if I left it in for seven hours, it most likely would have been completely finished. So if you ran yours at 10 amps, it would be done in about two days.
See ya next time, kids, on Hanna’s Bug!
As always, this show is filmed in front of a live studio audience.