The best method of surface rust removal?
 

What's a good way to get the surface rust off my exhaust components (cat, muffler, crossover pipe in particular) without sand blasting. Has anyone used Naval Jelly, or other acid? One particular website stressed that you must paint the part after using Naval Jelly with an oil-based paint. Obviously, I don't want to paint my exhaust, any advice?

What's wrong with sand blasting, that's the best way to get into nooks and crannies.

Also, what's wrong with hi-temp paint assuming not Stainless muffler and the other components? VHT makes some 1600F wrinkle paint that looks good.

Or you can always send stuff off to Jet Hot (NICE stuff) and relatively cheap for a gorgeous satin silver life-time finish.

JETHOT The Hottest Header Coatings! Jet-Hot, jet coat, hot jet, headers, coatings, sterling,Header coating, Ceramic coating, corrosion protection, Metallic Ceramic Coatings, MCCI, metallic ceramic, exhaust coating, performance coating, temperature re

Wire brush, then diluted phosphoric acid. Soak 20 minutes and wash it off.

If you don't paint the exhaust the rust will return.................

Blasting is indeed the best and saves you eating rust dust. However I do use the wire wheel alot on an electric drill (wear a mask and eye protection) and have good results when you clean clean clean after stripping. I've not tried phosphoric acid. I use prep solvents like 3M adhesive remover and continue using until the wipe cloth is no longer picking up a lot of "dirt" when you wipe the part down.

I've had good luck on exhaust parts with POR-15 high temp and also a cold galvanizing paint by LPS. The VHT is nice, but sort of a pain with the heat cycling they ask of you in the directions.

Jet Hot is also nice, but it's NOT cheap. I was quoted $225 to do a pair of 911 shorty steel headers. That's almost what the headers cost!

brush lightly then use a rust reducer & paint

or check out the Eastwood brush on non-paints...

I've heard Oven Cleaner works great on stripping paint, anyone tried it on rust?

Thanks everyone, a lot of good ideas..