Using The Zinc & Lye Process

by Ken Myers

I started using the zinc and lye method in 1979 as a great way to clean an artillery projectile or any iron item. For example, the process was used on two bayonets dug by me (one in Texas and the other in Virginia) and I can turn the retaining bands on each of them. My preference with the zinc and lye method is that it stops working when the rust has been removed from the iron item. Consequently, I can leave an item for a long period of time without deterioration of the item.

CAUTION: THIS PROCESS CAN CAUSE SERIOUS BURNS AND/OR EYE DAMAGE IF NOT PERFORMED CAREFULLY. The lye solution is very caustic and can burn your skin or damage eyes or be fatal to children, pets, or animals.

FOR SAFETY:

1. Wear rubber gloves

2. Wear protective eye wear

3. Wear long sleeve shirt

4. Wear long pants

5. Wear socks and shoes

6. Wear filtration mask


SUPPLIES NEEDED FOR ZINC & LYE PROCESS:

1. Two plastic buckets or 2 long plastic pans depending on the size of the item to be placed in the zinc and lye.

2. Can of Red Devil Lye ( I find that this brand works best as some lye products contain filler material. Red Devil Lye can be purchased at most grocery stores).

3. Zinc (scrap zinc from scrap metal yards, zinc jar lids, zinc wall anchors from Home Depot/Lowes, zinc bars from boat dealers).

4. Paper towels.

5. Spray paint - My preference is KRYLON clear satin finish.

6. Plastic newspaper bags.

7. Silver duct tape.

8. Linoleum knife.

9. Small hammer.

10. Small finishing nails.

TO START PROCESS:

1. Place zinc in bottom of bucket or plastic pan. I go heavy with the amount of zinc as you can reuse the zinc which is left. (The zinc will dissolve during the zinc and lye process).

2. Place iron item in bucket or plastic pan.

3. PROTECTING YOUR EYES AND SKIN FROM FUMES, carefully add water - DO NOT HAVE THE WATER COME IN CONTACT WITH BRASS OR LEAD - for lead sabots on Hotchkiss projectiles, I wrap the lead with two layers of plastic newspaper bags. On top of this, I wrap with silver duct tape. For cannonballs, I have made stands which allow me to keep the brass fuse out of the zinc and lye solution. For projectiles such as a Parrott, I bring the water level up to where the fuse starts (note: you will get some discoloration from the fumes given off by the lye - some people like to coat the fuse with Vaseline prior to the zinc and lye process).

4. Wearing the above 6 items listed FOR SAFETY, carefully sprinkle lye from the container into the bucket of water.

5. Let the item soak in the zinc and lye solution. For example, for a projectile, I leave initially in the solution for 4 hours and then while wearing the 6 items listed FOR SAFETY, I remove the item and place in a bucket of clean water to rinse. I then dry with the paper towels.

6. I take the item and scrap off the loose rust using a linoleum knife. DO NOT BEAT DIRECTLY ON THE ITEM WITH A HAMMER AS THIS CAN DAMAGE "GOOD" METAL AND ALSO CAN BE DANGEROUS IF THIS IS A PROJECTILE. If the rust is caked on heavy, you can tap the top of the linoleum knife blade to help you remove the layers of rust. Remove only the layers of rust which can be removed easily.

7. As needed, repeat steps 5 & 6. Depending on the location of the dug item, soaking times can vary. For example, a projectile from Vicksburg, MS will be generally cleaned down to the good metal in 4-5 hours with all rust removed. A projectile from Atlanta, GA can take as long as 3-4 DAYS of repeating the cleaning and soaking process as indicated in steps 5 & 6. BE PATIENT AND REFRAIN FROM STRIKING THE ITEM DIRECTLY WITH A HAMMER TO REMOVE THE RUST - THIS WILL ONLY DAMAGE THE ITEM AND COULD BE DANGEROUS IF IT IS A PROJECTILE.

(NOTE: THE NICE FEATURE OF THE ZINC AND LYE PROCESS IS THAT ONCE THE RUST IS REMOVED, THE PROCESS STOPS AND WILL NOT BREAKDOWN "GOOD" METAL)

You do not have to be on a time clock.

8. When the item is cleaned of all rust, you can use a finishing nail to remove small specks of rust from areas such as the base of a Parrott projectile.

9. Remove plastic bags and duct tape as applicable.

10. Do a final rinse in clean water and dry with paper towels.

11. After the item is completely dry, spray with KRYLON satin finish clear spray paint.

12. Dispose of the lye in accordance with regulations for your area. DO NOT LEAVE THE LYE WATER WHERE IT IS EXPOSED TO CHILDREN, PETS, OR ANIMALS AS THE LYE WATER CAN CAUSE INJURY OR DEATH IF TAKEN INTERNALLY.
 
 
 

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