Best Way to Clean Rusty Bars?

[w30bob]

Hi Guys,

  Been pondering the best way to attack a rusted bar.  Not something pitted beyond 'worth saving', just surface rust of varying degrees and discoloration.  On the old 50's bars the finish was pretty rough, so pretty easy to duplicate the original finish with a belt sander.......after the rust is removed.  60's bar seem better finished, so will take more work.  When I asked how to clean up hand saw blades a week or two ago someone (sorry, don't remember who) suggested this;

"A DA sander with 180 grit would most likely clean the rust off. Then use 220 to polish. I have seen a feller take a 1/4 sheet sander and use it to work a Scotchbrite pad with WD-40 on a machine tool bed to clean it up. Worked great."

  So I plan to try that!  But was wondering....in the interest of saving time.......what else have you guys tried that worked well........and NOT so well?.  Naval Jelly?  Steel wool?  I've got a Wiz 80 bar soaking in Evapo Rust now, which I'm sure will clean up nice........but that stuff gets expensive after awhile.  I'm sure this topic has been discussed probably multiple times previously............so how about giving me the quick summary?

thanks,
bob 

[undee70ss]

houseofhomelite.proboards.com/thread/7056/rust-removal-electrolysis

[MI Old Saw]

Electrolysis works great, as does the chemical rust removers. I use the gel version of Krud Kutter on lots of stuff, and it does a great job. I then use a small 2.5" buffing wheel to go over it after washing off.