what is best abrasive tool to clean rusty 1/8" thick steel plate?

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I got a couple of 3'x10' sheets x 1/8" thick steel from the local junk yard. for $50.I'm going to put them over my existing wood bench to give me more workspace area. to set up aluminum welding projects. ONly problem is they are rusty as heck, they were sitting outside for probably years. I have a cheap harbor freight 7" polisher with hook and loop pad (a poor man's grinder?) and lots of 4.5" angle grinders.  a small cheap handheld belt sander, and a huge drum wood floor sander I  used on my wood floors when I installed them.I ususally get my abrasives from AAAabrasives.comwhat would be best abrasive to clean up this sheet metal? I tried some 150 grit 7" discs and they clogged up fast.. Tried rope wire brush on 4" grinder and that got the loose stuff off but just smeared around the finish and never got down to bare metal. Since I hardly ever work wtih steel I'm guessing there is some abrasive that I should be using that I am clueless about. I used standard steel grinders and cut off wheels for years until I discovered ones made especially for Aluminum at AAAabrasives. So I know I'm ignorant on a lot of this stuff.
Reply:150 grit is really fineget some 60 gritEd Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:I agree with the 60 Grit.I used sanding flap disks like these, they work a treat for removing rust
Reply:These discs work pretty well for rust removal.http://www.aaabrasives.com/products/...cs-type-27-4-7Also available from some hardware stores. I like the Norton rapid strip available from OSH. Just make sure they look like this (color is not important, some black, some blue, some marroon):http://media.photobucket.com/image/r...CleanStrip.jpgIan TannerKawasaki KX450 and many other fine tools
Reply:The "...best abrasive tool to clean rusty 1/8" thick steel plate..."  I start with a knotted wire wheel.  If I don't like the results I go on to a flap disk.  If I am still not satisfied I use a hard wheel grinder.  I most often skip the flap disk and go right to the hard grinder.  But it depends on how rusty and from where it is to be removed and why.  If I am going to MIG that area I use the hard wheel.  If I am going to paint with Rustoleum primer and top color then the knotted wheel is usually sufficient.Both the flap disk and the hard grinder take off metal and can do so pretty fast, too, so go easy.I love the results I get from these little beauties:  Norton Product Code 07660704015But at $10 - $15 each they really are a luxury to be used sparingly on only really special projects and surfaces.- MondoMember, AWSLincoln ProMIG 140Lincoln AC TombstoneCraftsman Lathe 12 x 24 c1935Atlas MFC Horizontal MillCraftsman Commercial Lathe 12 x 36 c1970- - - I'll just keep on keepin' on.
Reply:Originally Posted by MondoI love the results I get from these little beauties:
Reply:When looking at 60sqft, I'd definitely be using some naval jelly or similar rust dissolving gel.
Reply:knotted wire cup wheel would be my choice . grinding wheels  are more aggressive than i like , and i usually end up removing too much -or making it worse than before i started .i do like the rex-cut linen wheels for blending steel , but @ $12 each they cost too dam much.@ $4 a gallon muratic acid is attractive . just be sure to have plenty of baking soda on hand to neutralize the thing when you're doneLast edited by tnmgcarbide; 01-11-2013 at 03:53 PM.Miller S60 feederCobramatic push/pull feederMiller CP-252tsLincoln Tig250/Tig250Lincoln weldpak 100 -italianC-H 90A- italianHarris & Victor O\Afull manual & CNC machine shop
Reply:Originally Posted by 7A749I'm not a big fan of using abrasives for rust removal.I use 36 grit for a lot of general grinding, but even the zirconia discs I have get munched in a hurry on rust. They seem to glaze over.A what quality abrasives cost, I would stick to a wire wheel or chemical agent.IMHO of course
Reply:Don't put too many clothes on w/ a cup brush. They just love to grab clothes and aprons!!                                    MikeOl' Stonebreaker  "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:Yeah I saw some of those cool stripping discs but they cost more than I have invested in the scrap metal! I couldn't brag about how cheap I got it if it costs me double to get it sanded. In the end I spent about an hour today wtih the wood floor drum sander and 60 grit paper to finish one of the 3x10' sheets. I wiped it down with some evapo-rust inhibitor. still has a bunch of black areas, but it is good enough for a work bench table. I have to make a friend that I can place an order for steel next time. The local steel places prices are not so good when you only want a quote for one sheet of steel. Thanks for the advice. I'm deffinetely gonna pick up a few of the tools you folks mentioned.
Reply:Plain old pool muriatic acid takes rust right off of steel.
Reply:I would use acid as well. Brush it on let it set but don"t let it dry. Hose it off and treat with Zinc phosphate.
Reply:I just put it in an old bug sprayer and spray it on.  Watch which way the wind is blowing though.
Reply:the evaporust I use makes the rusted metal turn black, what color is the metal when you use muriatic acid?  I would like the coutner to look an even color, right now it is black with a bunch of silver sanding marks where I was able to sand through all the crud.
Reply:It just goes back to dull grey steel.  Obiously it will start surface rusting very quickly if you dont treat it with something.  But, if you use the acid to get the rust off, it will be short work to go over it with a sanding disk to make it all look the same.
Reply:Originally Posted by AluminumWelderIn the end I spent about an hour today wtih the wood floor drum sander and 60 grit paper to finish one of the 3x10' sheets.
Reply:Originally Posted by AluminumWelderI have to make a friend that I can place an order for steel next time. The local steel places prices are not so good when you only want a quote for one sheet of steel.