Clean Cast Iron Pans With a Battery Charger Rust Removal System
Battery Charger Rust Removal for your Old Cast Iron Pans
If you’ve ever found a rusty old cast iron pan at a flea market or pulled one from deep storage, you know how tough rust can be. Scrubbing takes forever, and store-bought rust removers can be harsh—not to mention expensive. Fortunately, there’s a little-known method that’s safe, powerful, and incredibly effective: Battery Charger Rust Removal.
This simple process uses electrolysis—sending a small electrical current through a solution of Borax and water—to lift rust off metal without damaging the pan. It’s a game-changer for cast iron collectors, DIYers, and anyone serious about restoring old cookware.
What You’ll Need
- A non-smart manual battery charger (6 or 12 volts)
- Plastic container big enough to submerge your cast iron pan
- 20 Mule Team Borax (or Arm & Hammer Washing Soda)
- Tap water
- Steel rebar or other sacrificial steel (NOT stainless)
- Jumper cables or clamps
- Protective gloves and eye protection
Step-by-Step: How to Clean Cast Iron with a Battery Charger
- Fill the plastic container with enough water to cover the cast iron pan.
- Add 1 tablespoon of Borax per gallon of water and stir until dissolved.
- Place the sacrificial steel in the container, making sure it doesn't touch the cast iron.
- Connect the positive (red) clamp to the sacrificial steel.
- Connect the negative (black) clamp to the cast iron pan.
- Plug in the charger and set it to a low amp setting (6V or 12V). Bubbles should start forming—this means it’s working.
- Let it run for 6–12 hours depending on the level of rust. Check periodically.
- When done, unplug the charger, remove the pan, and scrub off loosened rust with a brush. Rinse and dry completely.
Why Use Battery Charger Rust Removal?
This method is far less abrasive than sandblasting or wire wheels. It reaches into pits and corners that manual scrubbing can’t. If you collect vintage cast iron or restore cookware for resale, this technique gives results that look factory-clean without grinding down the metal.
Safety Considerations
Anytime you're using electricity near water, take proper precautions. Only use this setup in a well-ventilated area—electrolysis releases hydrogen gas, which is flammable. Never use stainless steel as your sacrificial metal—it can release toxic chromium compounds. Always wear gloves, eye protection, and unplug the charger before adjusting clamps or removing anything from the water.
Why Not Clean Cast Iron with Vinegar or Chemicals?
Vinegar can work in small doses, but it’s acidic and can damage cast iron if overused. Many rust removers are harsh, expensive, and leave behind residues you don’t want in your cooking gear. With Battery Charger Rust Removal, there’s no scrubbing, no harsh fumes, and no toxic residue—just clean metal ready for seasoning.
Preventing Future Rust
After you clean cast iron with this method, dry it immediately and apply a thin coat of oil. Bake it in the oven to season the surface and protect it from future rust. Store your pans in a dry space, and never leave them soaking in water. Regular use and light maintenance will keep them rust-free and ready to cook for decades.
Perfect for Restoring More Than Just Pans
While this article focuses on cast iron cookware, the method of Battery Charger Rust Removal also works wonders on other rusted metal items—like old tools, brackets, and workshop gear. If you’re a fan of restoring vintage finds or cleaning up your garage, this process can breathe new life into forgotten pieces. Just make sure the item is solid iron or steel and doesn’t include delicate moving parts or paint you want to preserve.
Many collectors rely on electrolysis for its ability to clean deeply without grinding away original material. Once you’ve done this process once, you’ll find yourself looking for other rusted treasures to bring back to life. Just be cautious and avoid using this on anything with electronics, plating, or unknown metals. As always, do a test run with less valuable items to get a feel for the process before restoring something rare or irreplaceable.
Helpful Tip: Find More Great DIY Tips
Looking for more helpful advice? Find other great tips here.
Recommended Gear
Want to try this at home? You can find everything you need on Amazon, including:
Final Thoughts
Battery Charger Rust Removal is one of the most effective and surprisingly simple ways to bring rusty cast iron pans back to life. It’s safe, affordable, and works better than scrubbing or chemicals. If you're ready to restore an old skillet or clean up a garage sale find, give this method a try—you’ll be amazed at the results.
One of the biggest advantages of Battery Charger Rust Removal is that it’s repeatable. You can use it again and again without wearing down your cast iron or damaging surfaces.
ML Lamp is the owner of Kilroy Was Here. After his 20 years of working in Las Vegas in the entertainment promotions field, Mr. Lamp retired in 2002 from his job to pursue his passion for collectibles. Now as a guest speaker and author he’s living the dream, and sharing his warmth with You.