Tool Grinder

[Mayhem]

I wish I had a friend like Bob

John - get yourself a bag of soda ash (any pool supply shop will have it) and use electrolysis to get the rust off of those collets. I was going to link to the post I did on this but I cannot seem to find it

Essentially, mix the soda ash into a bucket of water and put some scrap metal in there and attach the positive lead of a battery charger to this. Loop some wire to the collets and suspend these in the solution, making sure they don't touch the scrap metal. Attach the negative lead to the wire holding the collets and hit the power. The more scrap metal, the quicker the process, as it works by line of sight.

Here is a picture of the bucket, into which I have placed some old weld mesh to the perimeter. There is also a lump of plate at the bottom (note the thin red wire). Also note that this is a photo taken after I zapped the chuck for 10 minutes.
   

Here is an out of focus pic of the 1/2" Rhom keyless chuck that I was given on the weekend. This thing is rusted solid.
   

Here it is ready to zap.
   

Here it is after 10 minutes. Still a long way to go but you will agree that is quite a difference.
   

Here is the bag of soda ash. I have used baking soda and it does work, but the process takes a lot longer.