Help with rusting stainless posts

[MetalMan23]

So perhaps this is because I used 304 stainless, perhaps it's the way I drilled the holes, perhaps it's the finish on the stainless, anyway, I'm in trouble and I need to figure out how to fix this pretty fast,

I clear coated the posts after fabrication, I thought that would help.

I would prefer to not have to replace everything here and lose a bunch of money.,

Any ideas? Could I clean it well and coat with a 2k clear?

Clear powder coat?


If I used 316 would it have made a difference?

I've seen other cable rails that are rusted out as well after years, the problem with mine is that it's only been a few months,

[MetalMan23]

This is not something I can replace a few posts at a time to help spread the cost out, I'd have to do everything at once and spend a few thousand dollars

Sent from my moto g power using Tapatalk

[tapwelder]

I would guess the issue is the sharp edges, cable vibration and the salty environment. I am just speculating. Based on location of rust and even the corner on the tube. Perhaps clean and add insulators?

The only exterior cable rail, the cables showed rust spots in short order. I suspect shop dust. Since it was so rapid.

Brett, from Down Under was on here recently. He does a lot of cable rail. Perhaps he will offer some assistance.

[psacustomcreations]

Have you tried some oxalic acid to remove the oxidation?

When I made a sculpture with a mix of mild and stainless, I had some rusting spots on the stainless. I applied some of that acid on the spots and it removed them. The stainless did not rust again. I do not remember what grade of stainless I used.

Sent from my SM-G930V using Tapatalk

[MetalMan23]

I would guess the issue is the sharp edges, cable vibration and the salty environment. I am just speculating. Based on location of rust and even the corner on the tube. Perhaps clean and add insulators?

Brett, from Down Under was on here recently. He does a lot of cable rail. Perhaps he will offer some assistance.

I'm sure that has something to do with it, I can try to get some plastic insulators,

Sent from my moto g power using Tapatalk

[MetalMan23]

Have you tried some oxalic acid to remove the oxidation?

When I made a sculpture with a mix of mild and stainless, I had some rusting spots on the stainless. I applied some of that acid on the spots and it removed them. The stainless did not rust again. I do not remember what grade of stainless I used.

Sent from my SM-G930V using Tapatalk

I saw on a cable rail website, they sell stainless cleaner to remove oxidation, I could try that, they also sold something they claimed passivated the stainless, which I'm sure would help if it worked.

Any opinions on the 2k clear coat?

I guess if it was an issue with the sharp edges, the clear wouldn't solve that.

Sent from my moto g power using Tapatalk

[Bls repair]

This what happened to my stainless pipe and plate after I hit it with a carbon steel wire brush . If using a grinding wheel it has to be new with no contamination.
Is the cable stainless or galvanized? If galvanized this may be where rust is coming from

[MetalMan23]

This what happened to my stainless pipe and plate after I hit it with a carbon steel wire brush . If using a grinding wheel it has to be new with no contamination.
Is the cable stainless or galvanized? If galvanized this may be where rust is coming from

The cable is 316

Sent from my moto g power using Tapatalk

[psacustomcreations]

I have used rattle can Rustoleum on a few of my stainless items but not 2K.
The rattle can will drip or run in a heartbeat if you are not careful.
I used it mostly to lessen the fingerprints and am not sure if it would help your situation.
Edit: I would wager the cleaner you see is similar to the oxalic
Sent from my SM-G930V using Tapatalk

[psacustomcreations]

Phil,
Shoot me a PM with your address and I will send a snack bag or ziploc bag of the stuff you can try for free.
I bought a 5 pound bag and have only used a few ounces.


Sent from my SM-G930V using Tapatalk

[RideKTM350]

I have used Citrisurf products before with great success, look under the "rust removal" tab.

http://citrisurf.com/

RideKTM350

[Broccoli1]

http://www.sperkoengineering.com/html/Rust.pdf

from 2014 but there are some suppliers listed for Rust removal on stainless.

[albrightree]

https://www.mcmaster.com/passivating-gel

For about $28 Mcmaster will have it for tomorrow. Probably available on amazon somewhere.


The gel works well on vertical surfaces, even in the sun. I often use the white scotch brite pads with this because it wont affect the finish much where you clean. Using grey or red scotchbrite is good for polishing(rough).

[metalman21]

What did you use for clearcoat? You probably will have to remove the clear to get to the rust.

[MetalMan23]

What did you use for clearcoat? You probably will have to remove the clear to get to the rust.

Rustoleum, yeah I'll probably have to do that

Sent from my moto g power using Tapatalk

[Welder Dave]

Stuff they use for removing rust on chrome like vehicle bumpers might work too. Any auto parts store should carry it.

[John T]

I'm sure that has something to do with it, I can try to get some plastic insulators,

Sent from my moto g power using Tapatalk

Yeah I would go with insulators after neutralizing the rust.... but it still looks like a bunch of labor... prolly have to disassemble the whole thing to drill bigger holes for insulators...
might be easier to clean the rust, repaint and use plastic coated cable...... WITH insulators to boot!

salt water is kickin yer azz.

[tapwelder]

Is heat or disturbance from drilling enough to cause the need to passivate?

[Capt B]

I don't have a lot of experience with cable rail. But work on ocean front amusement rides and boats. In my experience 304 stainless doesn't last a season before showing some rust which is why we use 316 for anything stainless close to the ocean. I do hope you figure out a way to deal with it without replacing it though.

[l0w n slow]

What kind of drill bit did you use ?

From my experience working in the field , we typically use cobalt end mill drill bits for stainless and cobalt bits . Regular drill bits introduce carbon to the stainless sort of like using a carbon brush on stainless . Itll make it rust .
Sent from my SM-G973U using Tapatalk

[chewinggum]

What kind of drill bit did you use ?

From my experience working in the field , we typically use cobalt end mill drill bits for stainless and cobalt bits . Regular drill bits introduce carbon to the stainless sort of like using a carbon brush on stainless . Itll make it rust .
Sent from my SM-G973U using Tapatalk

That's what I'm thinking. The rust you see is drill bit contamination. Once you clean it off real good, it won't come back.....Hopefully.
CG

[tapwelder]

I would expect rust around the bolts it were from a drill bit. Also if it has an intact clear finish, then there should be no rust. Many years ago it was not unusual to find a baluster fully deteriorated underneath powder coating. Always caused by porosity at a higher location.

I suspect the coating got compromised and salty mist is leaching, given the spread out pattern caused by dripping and capillary action. Still just speculating?

[davec]

I recall you asked about 304 vs 316 a while back. 316 is the one for Oceanside applications, outdoors. But either way you need to passivate after fab and welding. Find a metal finisher that can do it (or electropolishing if you want it shiny). Build that into your price in the future. If you remove the posts and get them passivated it should greatly help, but you are still stuck with 304 where it should be 316. You will probably have to eat the cost this time, but should plan for it.

[Welder Dave]

Wonder if something like this could work.

https://www.walter.com/products/weld...ox/surfox-mini

[MetalMan23]

Phil,
Shoot me a PM with your address and I will send a snack bag or ziploc bag of the stuff you can try for free.
I bought a 5 pound bag and have only used a few ounces.


Sent from my SM-G930V using Tapatalk

Pm sent

Sent from my moto g power using Tapatalk