Rust Removal using Electrolysis

rebeldart said

I've done this quite a few times and if you don't have a sandblaster - it works every bit as good, just takes awhile longer and your best to wire wheel after to clean off residual. I use a battery charger but have noticed the leads get smokin' hot - what's up with that ?

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There is very little resistance in the solution so you're charger is cranking every amp it can through the circuit trying to keep up. Try putting an automotive light bulb inline...like a tail light bulb. This serves as a makeshift current limiter and will protect your charger. Works great and may prevent a nasty house fire too. I think that's even mentioned on one of the sites linked earlier in this thread.