Phosphate Conversion Coatings: The DIY Rust Fix That Also Protects

Before you throw away those rusty wrenches and engine fasteners, learn how a DIY phosphate conversion coating can restore them and guard against future corrosion.

By
Drew Frye
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Rescuing tools. The foreground wrenches are common enough and were found in the bottom of a rusted tool box. They are probably from the 50s and 60s. The background wrenches are over 100 years old and had a hard life. After treatment they work just like new, though they are now just for display—they’re very heavy. (Photo/ Drew Frye)

In the process of rediscovering my machining hobby, I dug out my long-ignored collection of machinist tools from a great uncle who worked in torpedo development at the Washington, DC Navy Yard as a machinist. Taps, dies, and some more obscure tools specific to metal lathes and milling machines. In the process of recovering these tools, I explored de-rusting chemistry (they were mostly well-stored, but many were 80-100 years old, so some light corrosion was universal) and common surface treatments. I am a chemical engineer, after all.

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Drew Frye
Drew Frye, Practical Sailor’s technical editor, has used his background in chemistry and engineering to help guide Practical Sailor toward some of the most important topics covered during the past 10 years. His in-depth reporting on everything from anchors to safety tethers to fuel additives have netted multiple awards from Boating Writers International. With more than three decades of experience as a refinery engineer and a sailor, he has a knack for discovering money-saving “home-brew” products or “hacks” that make boating affordable for almost anyone. He has conducted dozens of tests for Practical Sailor and published over 200 articles on sailing equipment. His rigorous testing has prompted the improvement and introduction of several marine products that might not exist without his input. His book “Rigging Modern Anchors” has won wide praise for introducing the use of modern materials and novel techniques to solve an array of anchoring challenges. 

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