Topic: Lazy Man's Exhaust Rust Removal

[pjandrew99]

Can you submerge a baffled, rusty exhaust in diluted phosphoric acid without ruining the packing?
Please say yes. 

[Alan F.]

Good question.
I'd suppose wet muffler packing would be a bad, bad thing. How would you dry it out? Would you want to rinse it in place? Would that put the pipe at risk for further rust to develop?

I think I'd remove the baffle and packing, remove the packing from the baffle. Soak the pipe and baffle separately. When done, rinse, dry with a heat gun or leave out in the sun. Then spray the baffle and interior of the pipe with high-temp paint, maybe more than one coat.
Then re-wrap the baffle and reassemble with pop rivets.

[Dunk]

No, wet packing does not work well. You'd be hard pressed to rinse all the acid out of it too while flushing the acid off the rest before your final coat/treatment/whatever.

[WideAWAKE]

Do what chromers do when replating/cleaning an old exhaust.

Plug the ends (and baffle screw holes) with rubber plugs.

They sell em at the ace by my house big enough to plug in end.

[pjandrew99]

Thanks guys!
Plugging the ends sounds doable. However, there is a seam running down the middle that could be an entry point.
I'll take a closer look today and make a decision based on the info above. Much appreciated!

[newday777]

If you are looking to get rid of the outside surface rust on the exhaust, get some gel rust remover, brush it over the surface and cover it with plastic food wrap( to slow down evaporation), let set a couple hours  then use (4)0000 steel wool or aluminum foil crumpled into a ball and very gently scrub the rust off(too hard and you'll scratch the chrome off) then rinse off.

[jgger]

Don't forget to plug the weep hole also.

[Kelly E]

I cleaned up the rusty but intact exhaust on a 70' CB 450. I used a soft brass brush and Scotch Brite pads. I dipped the brush and pads in EvapoRust and gently scrubbed the rust off. It worked out great. I've tried putting exhaust system parts in the EvapoRust but it ruins the EvapoRust.

[pjandrew99]

Well, I'm a huge fan of diluted phosphoric acid and letting it do the work for me. However, I decided that I didn't want to take the chance of it getting into the packing.
Keeping in mind that this exhaust was heavily rusted, I used Permatex Rust Dissolver and 0000 steel wool. Initially tried just the steel wool and WD-40 but that was not enough on the heavily rusted areas. The Permatex/steel wool worked well. It took a couple of applications in some areas. I suppose the Loctite version would be similar. It did require plenty of elbow grease especially in areas where the chrome was completely eaten away. Its a pretty rough exhaust but looks decent now.
Appreciate all the help!