Pantry Potion: Rusted Metal

I love the romantic decay of rusted metal.  The colors and shapes speak to years of use, storms passed and time gone by.  In a haunt, a rusty bucket can hint at neglect, abandonment or perhaps even a nefarious use.  Here's how to get a perfect patina that doesn't require years of patience, just some pantry staples.  

I'm going to show you how to do a galvanized metal object.  If you're using a tin or unsealed object, you can skip Step 3 as noted below.

What you'll need:

• Metal Object
• Lemon Juice (for galvanized objects only)
• Distilled White Vinegar
• 3% Hydrogen Peroxide
• Salt
• Paper Towels
• Plastic Tray or cardboard box (optional)
• Gloves
• Clean BBQ Brush
• Degreaser (Goof-off)
• 2x Spray Bottles
• Matte clear Polyurethane spray

I picked up the bucket at a favorite supply source - the kitchen store - for a mere $5.99.  They're great for Hydrogen Peroxide, gloves, BBQ brush & spray bottles on the cheap as well.  The rest you can find at your grocery store.  Look for store brands and "pantry staple" sales year round.

Wear gloves to prevent oil from your hands from getting on the metal and interfering with the rusting solution.

Step 1: Degrease the metal with the degreaser to remove any dirt, oils or finish that will prevent the rusting solution to work.  

Step 1 - Degreased and ready to go

Step 2: Use the BBQ brush to distress the metal, taking care to brush in various directions as you go (I like alternating circles and X's).  I find this helps expose the metal to the rusting solution effects.

Step 2 - already looking less shiny

Step 3: Soak the metal in a bath of 90% vinegar to 10% lemon juice.  For larger objects, wrap metal in paper towels soaked in the solution. Ensure as much contact between the object and towels as possible and try your best to keep the towels wet.  A spray bottle of the solution is handy for this step and can even be used to apply the paper towels (spray object, apply towel, spray towel).  Let soak overnight. (Skip this step if your not using galvanized metal).

Tip: This is a messy project so I highly recommend using something to protect your work area.  A plastic tray can act as a catch basin and the paper towels as wicks, their ends soaking solution pooled below.  Mixing tubs and Plastic planter saucers are great for this.

Step 3 - Bath time!

After just a few hours the shine is gone

16 hours or so later.  Already some rust forming. Upper inside
didn't have a nice contact with the formula soaked towel leaving
it somewhat shiny.  Grr.

16 hour mark, other side

Step 4: Mix the following in a spray bottle: 4 parts vinegar to 2 parts 3% hydrogen peroxide to 1/2 part table salt.  Mix VERY WELL, dissolving all salt crystals before using.

Tip: This next step works best with a little heat so if possible, work in direct sunlight, allowing the metal to warm up.  The heat acts as both a catalyst to the reaction in addition to causing it to dry quickly.

Step 5: Lightly spray the metal with the solution from Step 4.  Allow to dry and repeat until you reach the desired effect.  Be mindful of using too much solution as it can drip and run, leaving the rust in the plastic tray below rather than on the metal where we want it.  This process can take just a few hours or days, it's up to you.  I find leaving things out exposed to the elements at night and spraying during the day for a couple days works best.

Step 5: After first 10-12 sprays..

About another 20+ sprays later...

40+ sprays, a night out, hit by the sprinklers...

Step 6: Seal object with Polyurethane spray.  The rust is powdery and can come off on your hands so it's a good idea to fix the patina in place.  Especially if you're doing a beverage bucket and plan to have ice/water inside.  For beverage buckets, I'd suggest either skipping Step 3 on the inside or, in addition to sealing, use a plastic liner/bag that can be held in place with magnets so that the beverages don't wind up swimming in rusty water.

Step 6: Sealed

A slight change in angle and colors shift, so cool!

Finished product in disguise as a cool way to chill beverages...

262 days till Halloween...