Over the years I have tried various methods of rust removal for small to medium components. The best I have found is something from Bilt-Hamber called DeoxC. It is a white powder you dissolve in water and than soak the rusty parts in for 24 hours. Very rusty callipers come out looking like new. Only one slight problem, the stuff is expensive. Started looking at electrolytic rust removal last night and came across a thread that stated that DeoxC was nothing more than Citric Acid. A bit more internet research and I am sure of it, at £20 for 5 kg this will make 50l rust remover enough to soak entire axle casings etc. What I like about this method is that it is kind to seals and any other non ferrous part. It does not remove paint unless there is rust underneath, however it will not be effective if the part is covered in old oily crud. You can also add wallpaper paste to the solution to give you something you can paint on and leave overnight, not as effective but saves time with the wire brush.
I am also going to get some phosphoric acid as a final treatment. This, to all intents, passivates the steel giving it good corrosion resistance, it is the active ingredient of Naval jelly and (I think) Jenolite. Again it works out so much cheaper to use the base chemicals.
If you do decide to have a go ,as with all chemicals remember to read up on safety instructions and wear the right protection
Tim
Rust removal
Re: Rust removal
Sounds interesting, might have fro give that a go in future, I get bored of spending hours with a wire brush attachment on the angle grinder 