How to get rid of major rust on top plate of welding table?

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Im building a welding table from some scrap steel that this steel plant was liquidating at a decent cost ($0.45/lb) the top plate i will using will be made using (2x) 9' x 22" x 0.539" steel plates (Grade a992). The problem is the surface rust is a bit more extensive then it seemed when i was buying the material. The 16"x16" area the i did took me 2hrs and 2 $7 grinding disks. I would like to have the plates blanchard ground but it seems the largest grinder in my area is only 40" so now i don't know what to do? Any Ideas?This 16"x16" area took just about two hoursThere is even some pitting....
Reply:7inch grinder, cup brush and a couple flap disks. Have fun
Reply:I went through the same thing not that long ago.   I've concluded there just isn't an ideal way to do this, except for a ****load of grinder time.    I had a 5" concrete grinding cup stone in my tool box left over from a patio project, which actually worked like a mini, inaccurate, hand-held blanchard grinder that actually seemed to work well:A little cleanup from a flapper wheel afterwards, and I had a nice table top.
Reply:That's not really major rust. Like mentioned, wire cup, flap disks, forget those itty bitty pits. Welding tables seem to turn into beauty contests somehow. The iron you slap on there don't care if it is a thing of beauty. The hammer you schmack it with don't care if it is a thing of beauty. Your welder don't care if it is a thing of beauty.  Will it function as a welding/work table? You bet, just fine."The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:Sand blasting would be fastest method
Reply:have you thought about having it sand/shot blasted? if this is just a welding bench there's no need for it to be nasa smooth. i hope you're not contemplating welding those plates right across instead of skip welding?i.u.o.e. # 15queens, ny and sunny fla
Reply:Any mobile sand blasting buddies around i agree that would be best Sent from my iPhone using TapatalkUsing Tapatalk
Reply:I know there are some rust remover agents, and just in case you were thinking about them, save your money! They are good for little things. Not full sheets! I would just have at er with a grinder with flap disks and wire wheel!
Reply:Muriatic acid (pool acid) will take the rust right off.
Reply:If it took 2 hours and 2 grinding wheels to clean up 16"x16" you are doing it wrong. Use a grinding stone to remove most of it then smooth it up with flap disk if needed. 7-9" grinder shouldn't take long to clean it. If it was mine I would just hit it with a wire wheel, or have it blasted.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:Workshop Hero - Metal Rescue
Reply:I encourage rust on mine, not lumps of rust but rust because weld spatter wont stick as easy.
Reply:Do you have a 7''/9'' grinder ?  Get some of these sanding disc and be done quick. http://www.amazon.com/Milwaukee-48-8.../dp/B00004XPZR  i use some 80 grit and they really make for a smooth surface not like using a grinding wheel. I think a grindstone or disc removes too much. Get the biggest part and from use it will get cleaner. Your always gonna a sanding disc for clean up on the top anyway.
Reply:Originally Posted by SandyThat's not really major rust. Like mentioned, wire cup, flap disks, forget those itty bitty pits. Welding tables seem to turn into beauty contests somehow. The iron you slap on there don't care if it is a thing of beauty. The hammer you schmack it with don't care if it is a thing of beauty. Your welder don't care if it is a thing of beauty.  Will it function as a welding/work table? You bet, just fine.
Reply:I'd probably haul it outside and douse it with "The Works" blue toilet bowl cleaner.  A buck a bottle at the dollar stores and has a lot of Rodine inhibitor to reduce fuming and attack on the base metal. It is HCl (muriatic acid), just kinder and gentler."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:I honestly wouldn't worry about the rust just grind off a spot to put your ground clamp and weld on.Lincoln pro core 125 14''chop saw7 inch grinder,2-4.5 inch grinders,electric die grinder.Half inch drillAnd alot of hand tools
Reply:Originally Posted by AdvanI went through the same thing not that long ago.   I've concluded there just isn't an ideal way to do this, except for a ****load of grinder time.    I had a 5" concrete grinding cup stone in my tool box left over from a patio project, which actually worked like a mini, inaccurate, hand-held blanchard grinder that actually seemed to work well:A little cleanup from a flapper wheel afterwards, and I had a nice table top.
Reply:I just might have to try that with the abrasive to help speed things along.
Reply:Ditto the muratic to get it all off. Were it mine, I'd just use it clean. The black carbon that you are also taking off is a sort of natural anti spatter, and really tough protective film. So it the rust. Wipe of off with WD40 and just start to use it.
Reply:I bought a used table that had accumulated some rust. I tried a lot of different methods. I sprayed it with penetrant oil and wire brushed it, then tried to light it on fire. It wouldn't sustain flame. I tried diesel in the same manner and it didn't sustain a flame either. (When you're a hammer [or scrapper] everything's a nail [or needs to be burned]) haha. I finally gave up and just used the dang thing as it is. It seems to clean itself as its used. Btw it's 1" thick and 3x7'.
Reply:Ouch, 7 inches flap wheel on a 4.5" grinder+ wearing gloves=looking for trouble !   With gloves you will not feel the heat and once you smell insulation burning , it's too late... Don't ask me how i know
Reply:something like this, I use standard abrasiveshttps://encrypted-tbn1.gstatic.com/i...SL8Z-z4elmAwewbosses stuff:trailblazer 325maxstar 200my stuff:sa 200fronius transpocket 180100 amp Lincoln w/f97 f350 DITKevin
Reply:We've used HCL and then bicarbonate of soda to neutralize the acid.  Then if you don't keep heavy oiled it shall rust again
Reply:I have been cleaning mine with phospho or ospho for a few years and like it.  I hate having oil on my bench which is kind of hard because it's not a dedicated welding table just a steel work bench so it keeping it free of oil is hard.Last edited by kald; 02-09-2014 at 11:55 PM.Idealarc 250AC 225SVictor OA-older made in USA stuff.And a crap ton of other stuff.
Reply:Originally Posted by richeyWe've used HCL and then bicarbonate of soda to neutralize the acid.  Then if you don't keep heavy oiled it shall rust againis this to sit in the corner and look pretty or use?  If your planning to use it just dust it off and the cup wirebrush and rock on.
Reply:I've used the concrete cup stones as Advan has, but first thing you need to do TT, is go to a pawn shop and pick up a 7"-9" grinder.  The 4.5" grinders spin too fast for them, and the bigger grinders work better and faster anyways.Lincoln SA 200Esab Caddy 160Thermal Arc 201TSMiller Dialarc HFI don't like making plans for the day because then the word "premeditated" gets thrown around the courtroom....
Reply:Originally Posted by dubl_tI've used the concrete cup stones as Advan has, but first thing you need to do TT, is go to a pawn shop and pick up a 7"-9" grinder.  The 4.5" grinders spin too fast for them, and the bigger grinders work better and faster anyways.
Reply:Originally Posted by TTnicksocal... My question will i regret not truing up the plates when i had the chance and will all my projects suffer some from not having a true table
Reply:^ I think you're right Dubl t im just going to pass on the Blanchard grinding and use that money for some new tools that I need. Im still using a 7" wheel on a 4" grinder and burning my hand up (even thru two gloves)......... Tonight im going down to either a pawn shop for a used or home depot to get a new 7" angle grinder. Im almost done with one plate, hopefully I can finish this one up tonight...
Reply:Why are you trying to take the rust off? Its better than any anti-spatter you can buy. You can weld all day with no dingleberries sticking.Lincolin Power Wave 450, Lincoln Powermig 255, Lincoln Pro Mig 140, Lincoln Squarewave Tig 275, Miller Big 40 G(with Hobart Hefty suitcase), Thermal Arc 95S and Esab PCM875 in an already full machine shop.
Reply:Disk like these can be had for your 4.5 inch grinder. I use one like this on my drill and it's very fast at removing rust,mill scale etc. They don't last a real long time, but they work fast. Plus they are pretty cheap. Most hardware stores and Walmart carry them.~Scott~You can see what projects I'm working on on my Facebook page.https://www.facebook.com/pages/Bucke...3595655?ref=hlbucket_of_bolts on Instagram HTP 221 DV
Reply:Blanchard grinderVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:[QUOTE=TTnicksocal;3714461 That being said i have found that each plate has a very slight bow in them as shown in the pic. its not really bad and the bow is not found everywhere. But i would like the table to be plane and true when im done.[/QUOTE]Send CEP a PM and ask him about flame straightening those plates if you really want to get them flat. Might be able to get them flat when you weld it to the frame. I don't think a little bow is going to hurt anything though.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:When using muriatic acid just be sure to wear appropriate protection.  I use long heavy rubber gloves, good eye goggles and a respirator mask.  That stuff can be nasty if splashed on you or inhaled.
Reply:Yes if you buy concentrate like we do from a chemical supply house.  There is a particular order in which to mix it with water. I can't remember for sure but I think the HCL goes in the water  rather than Water Added to the acid.  Please confirm this with your supplier if you do get the concentrate.  This stuff will blind you, burn your skin and ruin your lung. Be very careful. For years we used it to boil out heavy equipment fuel tanks to remove the rust.  Good luck.  Your table is looking good
Reply:All water mixtures are wAter first concentrate seconded
Reply:Originally Posted by propanehotrodWhy are you trying to take the rust off? Its better than any anti-spatter you can buy. You can weld all day with no dingleberries sticking.
Reply:It's a nylon paint stripping disk. The one I posted is by 3M, but any brand should work.~Scott~You can see what projects I'm working on on my Facebook page.https://www.facebook.com/pages/Bucke...3595655?ref=hlbucket_of_bolts on Instagram HTP 221 DV
Reply:Originally Posted by TTnicksocali have found that each plate has a very slight bow in them as shown in the pic. its not really bad and the bow is not found everywhere. But i would like the table to be plane and true when im done.
Reply:Thanks for reminding me on the acid.  I thought I had it right with the water first and then add the acid.  Good luck on the table
Reply:Another way to do this. If the area that is crowned is small. Sometimes just heating small dots on top of the crown works too! Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Originally Posted by BucketOboltsIt's a nylon paint stripping disk. The one I posted is by 3M, but any brand should work.
Reply:This is a tractor torch.Just heat the top of the crown. It's really hard for me to explain via pictures on the Internet. Anyway I normally can't see anything unless I can touch it. Couple pictures of a bowed plate right in the center. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:^ ok Got it, thanks!....... ill report back.
Reply:See in the second picture where I applied the heat in the center of the plate? Notice the bow in the plate compared to the edge of the table? Heat expands, but when it cools, it contracts further than it was. Trick is, how much heat to apply!Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Awesome I see it now, i'll just go slow but at a constant speed and make sure not to put too much heat into it all at once...... would love to find one of the track torches you have im sure I could use it for all sorts of things.
Reply:Originally Posted by TTnicksocalwould love to find one of the track torches you have im sure I could use it for all sorts of things.
Reply:Thats alot of bs over some rust.  I just made a table with plate that was in the same shape if not a little worse and all I did was brush it and call it good.  I had a pretty good size project today and after I was done grinding off the spatter with a flap disk it was 10 times better. My point is you could call it good enough and work it clean.
Reply:[QUOTE= How to get rid of major rust on top plate of welding table?[/QUOTE]You call That rust? Sheesh, I thought it was something drug out of the Gulf Coast or Florida or somewhere or maybee Michigan where stuf rusts over-nite like some of weldors here xperiance with rust down South and North. I see your in SoCal. I think that red stuf on top of your steel is just what you get with the mill scale :laughing:It looks like its gonna be a very nice welding binch . 500lbs/per?I was gonna suggest pressure washhing with water but; after seeing what a nice piece: I woulda just washed it with anything mineral spirits, acetone , alchohol, leftover_budwiser but most likely; old gas or diesel. I mean anything but brake fluid would have been the last resort. Nowonder-Good thing I dont keep b-fluid around. Say, hydroscopic reminds me of low hydrogenLast edited by Insaneride; 02-12-2014 at 09:05 PM.Reason: hygroscopic is in liquid as low Hydrogen is solid In my ether