Are you tired of those rusty window rails or nooks and crannies of your favorite tools or jewelry?
Afraid that it's time to get rid of those essential metal objects without even being able to resell them because of how unsalvageable they are?
Well, there was a time when the slightest specks of rust in my favorite jewelry, tools, appliances, or even my idle barbeque grill made me anxious. Mainly because I thought there was absolutely no way to revive them by getting rid of those crusty layers.
But to my surprise, and about to be yours too, rust is no major setback and eliminating it entirely is way simpler than it seems!
Whether for heavy-duty or light rust removal, a wire wheel brush could be a blessing for someone like me or you. The perks of these devices are unmatched as you'll be able to use them conveniently on your own without needing a ton of additional chemicals.
In this guide, we’ll help you find the best wire wheel for rust removal from a sea of options. Keep on reading to know what features you should look into before buying one and the top products on the market.
5 out of 5
4.5 out of 5
4 out of 5
5 out of 5
4.5 out of 5
4.5 out of 5
Wire Wheel For Rust Removal : What To Look For Before Getting One?
1. Heavy-Duty Or Light?
This is the first and foremost aspect to decide on as the type of wire wheel you'd need for removing those rusty messes on your favorite objects depends entirely on this. The composition materials, wire type, configuration, density, etc. are all dependent on whether your operations are light, medium, or heavy-duty.
If your requirements are a mixture of it all, you may choose to opt for brush sets that come with all options to provide you the utmost flexibility and optimum performance every time.
These are basically circular wire wheels shaped like disks with wired extending out the edges. The wires can be either crimped or knotted according to your requirements of heavy or light-duty operations.
With a cup/bowl kind of structure, this type of wire wheels possesses the bristles/filaments on one side; like a stack of uncooked spaghetti in a container. Such a design can be ideal for more heavy-duty removals of rust.
They are also designed to be used on power tools that are portable; can come with either crimped or knotted bristles.
Suitable for more congested/small holes and finer details, tube wire wheels are basically vertical twisted wires with a bushy, vertical top. They can also be used in devices that are portable or drill presses.
- Stem Mounted
If you are short on space, these wheels could be your ideal bet to conduct light or heavy-duty removals. With the connection stems already attached to the wheels, it can be effortlessly used with electric & also air tools that are portable.
And as always, you can choose among crimped or knotted brushes; and wheel or cup models.
- Wide Face
This type of brushed can be created by stacking multiple disk/wheel brushes on a single arbor (the vertical stick on which the wheels revolve).
The end result is a rust remover wheel with a larger surface area than the diameter. And such models are usually customized upon special request of the customers based on their requirements.
2. Wire Material
The material used in the brush of the wire wheel is crucial as the strength and versatility of the wire wheels depend on it. Different materials are ideal for different objects. Options you can choose from include carbon steel, brass, and stainless steel.
Out of these, brass is the most versatile as it can be used on almost all metal types or other plastic or wooden objects. Carbon steel works well for Iron and carbon metals/steel. Stainless steel, on the other hand, can be ideal for stainless steel, brass, copper, aluminum, and even wood!
You may also run into more uncommon material compositions such as plastic, aluminum, or even nylon. While they may seem quite odd as brush options, but they can be more specialized with enhanced performance. For example, nylon bristles, though seemingly softer, can reach every corner like metal ones can't.
Whichever material you choose, ensure that it is of your utmost convenience according to the type of objects you intend to use the wheels for. But just to be safe, I'd suggest going for the option that will offer you the most flexibility and become your jack-of-all-trades!
Brass Wires: Virtually all metals, wood, and plastic
Carbon Steel: Carbon steel, Carbon metals, iron
Stainless Steel: Stainless steel, brass, copper, aluminum, wood
3. Filament/Bristle Configuration
Whichever wire wheel or brush you go for, the configuration of the bristles/filaments is a vital factor to consider.
This is because their arrangement will decide how flexible the brushes are and how finely they can clean every corner of the device and how heavy-duty its performance can be.
There are two basic configurations you are likely to run into. These are-
1. Twist/Knot Wire: These types of wire brushes basically comprise of clumps of bristles twisted into knots. Hence, they result in thicker points of action, unlike the crimped wire brushes.
Due to their stronger structure similar to a rope or cable, these kinds of wheels are the perfect choice for heavy-duty and more aggressive rust removal from bulkier and rougher objects.
2. Crimped Wire: This basically means that the wires remain separated individually- kind of like the bushy ends of a broomstick. This results in the wires being able to perform extremely well when it comes to reaching finely detailed objects.
They are also more flexible, can be ideal for light or medium-duty rust removal, and easier to use on irregularly shaped objects.
Choose a brush type according to your requirements but for more versatility and flexibility, it would surely be a smart move to invest in both.
The coarseness of the brushes of your wheel is determined by the diameter measures in inches or millimeters. The smaller the diameter, the finer the bristles and vice versa. Measured either in millimeters or inches, opt for models with the appropriate diameters for optimum performance.
Finer filaments are advised for light to medium-duty removals. They will also be more precise as they'll be able to reach finer areas than the others so that your objects end up being more flawless.
For heavy-duty operations, choose wider diameters or coarser filaments as they will not only facilitate more aggressive removals of thicker layers of rust; but will also be more durable. The following wire diameters below can provide you an insight into the coarseness of the wire wheels' brushes.
Very Fine: 0.005-0.006 inches; 0.13-0.15mm
Fine: 0.008-0.010 inches; 0.20-0.25mm
Medium: 0.0104-0.012 inches; 0.26-0.30mm
Medium To Coarse: 0.015-0.020 inches; 0.37-0.50mm
Coarse: 0.020-0.032 inches; 0.50-0.80mm
5. Spacing Of Wire & Wire Strength
While the spacing between the wires may not seem like much of an issue, it actually is quite critical. This is because the more densely the wires are packed, the more enhanced the performance will be when it comes to rust removal.
So the more heavy-duty your requirements are, the more densely packed filaments you should opt for achieving more flawless results.
The strength of the wires of your wire wheel is an essential factor too. The wires must only be slightly flexible when cleaning rusts for the most effective removal of rust or other contaminants.
If they are not sturdy enough, the wires will basically go everywhere except the point of action. Hence, you'll not receive your desired outputs after the removal process.
6. Brush Speed
This is measured in RPM or Revolutions Per Minute. To the inexperienced eyes, higher RPM may seem like the sweeter deal, but that is not the case entirely. You see, higher RPMs are most effective for more heavy-duty operations; whereas light-duty operations would require lower speeds.
So ensure that you choose a wheel with the appropriate speed according to your requirements. Too high capacities of RPM on a fragile object would become too aggressive and may even ruin the object entirely instead of salvaging it.
On the other hand, too low a speed would basically get any work done and result in ineffective rust removal entirely.
Hence, the best wire wheel for people with varying needs would be the one with flexible range of RPM. It can be adjusted for effective performance in both heavy and light-duty operations.
Keep in mind that most models usually specify the maximum capacity of the RPM. This will help you decide.
Whether you want to use your desired wire wheels with drills, screwdrivers, or grinders, etc., ensure that they are compatible with the device you intend to attach them too. The last thing you'd want is to end up with wheels that are not compatible with your device and hence, would go to waste.
You are likely to run into models that will work only with devices of their brands. But to enjoy more flexibility, the smarter move would be to go for ones that are not so brand-specific, and hence can work with almost any devices.
This will save your day when by any chance, you end up receiving a damaged product. Also, even if you realize after a while that this is not what you wanted, a reliable warranty from your seller or company is what will get you replacements or refunds. It will thus surely make your purchase a whole lot safer.
Wire Wheel for Rust Removal Comparison Chart
Type Of Wire
Configuration Of Wire
DEWALT Wire Brush, (DW4902)
Forney 72729 Wire Cup
Katzco Wire Wheels Brush - 2 Pack
Light, Medium & Heavy-Duty
HOYIN Wire Cup
2pc ALAZCO Wire Brush - Hex Shank
Fine Twisted Wire Brush
DEWALT Wire Brush, (DW4901)
Both Light & Heavy-Duty
Swpeet 3 PCS
1 Brass-Plated Crimped
TILAX Wire Brush Wheel Cup Brush Set 6 Piece
Both Light & Heavy-Duty
Our Top 10 Best Wire Wheel For Rust Removal Reviews in 2021
1. DEWALT Wire Brush, (DW4902)
With a lightweight mass of just 3.68 ounces, this super-light and compact wire brush is made of carbon steel. It consists of knotted wires too with a height of 0.20 inches. Hence, it can easily be the ideal choice if you require doing some heavy-duty rust removals.
It possesses a stem of 0.25 inches, which will make it effortless to attach to your desired tools. A holding plate in the interior will make sure that you can safely and consistently remove all the rust away.
This wheel can deliver the most stellar & efficient performance all thanks to its incredible speed of up to 20,000 RPM! Along with removing rust, it will also effortlessly cleanup weld, prepare surfaces, and deburr metals too!
2. Forney 72729 Wire Cup
If you’re looking to get a tool for cleaning up your fragile objects or other light-duty operations, this wheel could be your dream come true. Composed of steel, this wire wheel possesses crimped wires for reaching every nook and cranny of your detailed objects for flawless rust removal.
It will be easily compliant with any pneumatic or electric drills. This tool is lightweight and compact with a weight of 3.03 ounces and a diameter of just 2 inches. With an ideal speed of 6000 RPM, it will effectively handle the rust removal process without exerting too much pressure on your delicate objects.
This wheel can be super versatile too as not only can it get rid of rust, but will efficiently remove other contaminants including paint, weld spatter, dirt, scale, etc. Hence, you’ll get your favorite objects sparkling new in no time like a breeze!
3. Katzco Wire Wheels Brush - 2 Pack
In a dilemma between which brush to choose? Are you in need of performing both heavy and light-duty operations? Well, this amazing wheel-set by Katzco will have you covered.
Comprised of hardened steel, these cup wheels are extra durable and are less prone to wire-breakages. This 2-pack wheels set come with one wire wheel for heavy-duty operations thanks to its knotted wires of 3-inch height.
Got some lighter objects to take care of? Not to worry either as the other crimped brush will easily work its magic to handle your smaller requirements too! Hence, thanks to this set’s flexibility, it could be ideal for your homes, garages, automobile shops, household tasks, etc. and more.
With its shank of 0.25 inches, this will easily fit into any drills that you already own. And to ensure enhanced convenience and efficiency, these brushes, along with removing rust, can also remove paint and spatter. You’ll also be able to use them for accurate deburring effortlessly!
4. Forney 72759
If you’re searching for a top-notch tool for eliminating rust, then this model can easily make the cut. This disk-shaped wire wheel by Forney is composed of carbon steel and consists of twist-knotted wires for extremely heavy-duty operations.
And it can operate with a speed of 20,000 RPM to back up its heavy-duty performance. Ideal from cleaning the metal surface to get them all prepped up for being welded, these wheels will be able to smoothly and effortlessly remove rust, heavily corroded surfaces, spatter, weld scales, etc.
The twist-knots will be incredibly impactful on the surface with high speed to ensure so. This wheel will work best with right-angled grinders and its coarse wires will ensure you with effective and flawless cleaning.
5. HOYIN Wire Cup
This carbon steel cup wire wheel possesses knotted wheels to facilitate your heavy-duty requirements. With a diameter of just 3 inches, this wheel comprises of dual holding plates. It is constructed with an interior holding plate along with a hexagonal thread with its cover in between the exterior holding plate & the thread.
Hence, not only will it be safer and more convenient to use, but will also be more balanced and consistent. It comes with a 5/8"-11NC arbor and coarse wires of 0.020 inches will further enhance its heavy-duty performance.
This wheel is compatible with angle grinders within 4.5-5 inches and can be used for the most versatile array of purposes along with removing rust. These include roughening, descaling, deburring, edge honing, planing, structuring, stripping paint, weld seams, finishing, grinding, polishing, etc.
It can also be used for larger surface treatment of cast steel, steel, non-ferrous metals, metals, hand wood, soft wood materials, etc. It can work with speeds up to 12,500 RPM but can push it to up to 14,000 RPM too as for 1.2 times it has surpassed the ANSI standard.
6. Forney 72757
With knotted wires and a magnificent peed of 12,500 RPM, this cup wheel can easily end up being the best wire wheel for rust removal for all your heavy-duty needs. So all those rusty bulky equipment sitting in your home or garage can finally see the light of being as good as new in no time!
It is effortlessly to smooth and will perform as smoothly as cutting through butter almost. This wheel has been specially designed to work only on grinders that are right-angled. Cleaning larger surfaces including heavily corroded metals cannot be easier with this great gear by Forney.
This versatile piece of too, besides removing rust, can also remove burrs, weld scale, spatter, etc. too. Its carbon steel composition will also enable it to work on a wide array of metal types.
7. 2pc ALAZCO Wire Brush - Hex Shank
An ultimate lifesaver to clean your most fragile, delicate, and detailed objects, this wire wheel set could be quite the handy investment. Perfectly capable of reaching holes and corners that the other wheel-types cannot reach, these rust remover wire wheels look more like bottle-cleaner brushes.
They are comprised of stainless steel and possesses twisted wires and have an overall height of 4.5 inches. They can be spectacular to meet your light-duty cleaning tasks to remove rust and paint. These brushes can also be used for polishing if you desire.
The wire brushes come with 0.25-inch hex shanks that are quick-change and are ideal to be used on power drills. Even though they may seem to be fragile themselves but don’t underestimate their effectiveness when it comes to getting the job done. And even if one fails, the other will have your back.
Hence, if you've had your eyes out for the perfect gear for your minuscule tasks, these brushes could surely be a showstopper!
8. DEWALT Wire Brush, (DW4901)
Incredibly lightweight with a mass of just 2.89 ounces, this 1-inch wire wheel could be another choice of yours for getting light-duty tasks all done easily. It possesses crimped brushes and is constructed of carbon steel.
Though this may seem smaller than a toy, its capabilities can surely beat even some of the big guns when it comes to performance. This is because it possesses a gobsmacking speed capacity of up to 20,000 RPM! The wire bristles are also super coarse with a diameter of 0.02 inches.
As a result, this could easily be anyone's dream as it will provide a perk like no other as this single brush can perfectly be used for light, medium, and heavy-duty operations! Its 0.25-inch stem is compliant with 0.25-inch arbors and will be immensely convenient to use.
To further upgrade your de-rusting convenience, safety, and consistency, it comes with a holding plate inside too. Also, besides being amazingly durable, its wires have been tested to ensure that they can withstand and perform in accordance with the specifications demanded.
9. Swpeet 3 PCS
A package designed for those who require to perform all degrees of tasks, this trio of wire wheels are a lucrative investment that always doesn’t come so easily. This package consists of three cup wheels made up of carbon steel but they are slightly different.
Out of the 3 wire wheels, one of them comes with brass-coated wires that are crimped. And the best part about that is the fact that brass cab work with almost any material; even plastic, wood, etc. You will thus be able to effortlessly handle all your light-duty tasks without breaking a sweat.
The other two wheels are both comprised of knotted wires out of which, one of them is a knot-wire-end makes them adept for heavy-duty tasks. And speed capacity of 4500 RPM will ensure proper pressure exertion on your devices without compromising efficiency and effectiveness.
These wire wheels are incredibly durable too and are new and more resistant to wire breakage. They will also be conveniently attached to almost all drills and will effectively get rid of rust, paint, smoke, heavy corrosions, etc.
10. TILAX Wire Brush Wheel Cup Brush Set 6 Piece
This particular hexa-set by TILAX is for those who are all about crimped wire wheels. Each of them is either big or small, cup or circular, to provide you with maximized convenience and flexibility.
Now not only will you be able to work with larger and heavily corroded surfaces, but with the smaller ones, reaching the impossible areas would become a piece of cake! Even upon prolonged usage, the coarse and durable wires won't lose their shape. Every wheel will be able to attach to any drill due to its 0.25-inch stems.
This set, along with rush removal, can also remove paint, & burrs from metals or wood, and can also be used to level weld spatter. However heavy the tasks are, this wheelset could become the ultimate gear for enduring intense and heavy tasks. And a speed capacity of 4500 RPM will further enhance their performance.
You’ll be able to prep surfaces for the next coatings or other steps. This is called surface adhesion treatment and they are used before painting, electroplating, spraying coat, etc.
Along with rust removal, these wheels will facilitate grinding, and paint peeling off the surfaces.
Benefits to Use The Best Wire Wheel For Rust Removal
1. Compliance With Versatile Tools
Wire wheels can be super-versatile to use as you'll be able to effortlessly attach them to multiple tools such as drills, grinders, screwdrivers, etc. Hence, you can perform effortless rust removals effortlessly and conveniently no matter what type of compatible tool you own.
2. Effective, Efficient & Simple To Use
These are also super easy to use and will effectively remove the corroded layers of rust. The results will be visible almost immediately as the rust layers will be scratched off almost instantly!
3. No Chemicals Involved
This process of eliminating rust is also safe and hassle-free as you won't have to interact with powerful chemicals. Such chemicals can be acidic, toxic, smelly, and dangerous to work with. This is why wire wheels can be so much safer to use.
4. Minimum Base Removal
When removing rust with these tools, the advantage is that they only remove the corroded layers almost without removing the unaffected base metals. Hence, you will end up with a more flawless finish without losing the base metal itself.
Other methods of removing rust may significantly remove a noticeable portion of the metal too. This will result in the object becoming significantly thinner and weaker; thus affecting its durability and performance. Hence, using a wire wheel can easily be a safer option not only for yourself but for your objects too!
5. Can Prepare The Metal
Wire wheels for rust removal will even aid in prepping your metal surface by not only removing rust but also stripping off any old paints and smoothening the surface. This prep is mandatory if you intend to glue the metal or cover it with rubber or get a fresh new layer of paint on.
To provide you with the best of both worlds, wire wheels are not only super-effective and efficient, but are also amazingly affordable! With tools already available to attach them to, all you have to do is spend a few bucks and you should be good to go and get rid of those rusty layers in no time!
8. Ideal For Both Heavy & Light-Duty Operations
You will the widest range of styles with different brush forms, materials, and configurations which will offer you the flexibility to use these wheels for light, medium, and heavy-duty operations. Just pick out the perfect type according to your needs and get cleaning!
Frequently Asked Questions (FAQ)
1. Which Type Of Brush Should I Choose For My Wire Wheel?
Answer: The type of brush your wire wheel should have is entirely dependent on the purpose of your usage. If you look back to our buying guide discussed a while back, your brush configuration, coarseness, and spacing are entirely dependent on how heavy-duty your requirements are.
The material you'll choose will depend on the objects you intend to work on. And as seen previously, brass is the most versatile.
Out of all the brush types available which include wheel, cup, tube, wide face, and stem mounted, choose a model according to the delicacy of your objects and how fine the rusted areas are that need to be covered.
For example, tube brush can make the best wire wheel for rust removal from intricately detailed objects and tiny holes that other brush-types won't be able to reach.
For versatile work requirements, going for wire wheel sets can definitely be the slicker move!
2. How To Clean The Wire Wheels?
Answer: Are your wire wheels all clogged up from the suspended rust particles from extensive usage? Well, fear no more as you'll be able to clean them effortlessly in a jiffy!
The most popular and inexpensive way to clean them is by using vinegar & salt. All you have to do is submerge them in vinegar and add a good amount of salt and leave to rest for around 10-24 hours.
Soaking them in soapy water is also another way to go and you can just later brush them off against each other.
3. Which Is The Better Alternative For Removing Rust- Flap Disk Or Wire Wheel?
Answer: Flap disks can be the better option to remove rust in the surfaces you require to work on a flat, smooth, and wide. Otherwise, for irregularly shaped objects, wire wheels are your ideal option as only they are capable of reaching almost every nook and cranny.
4. How To Connect To Angled And Benched Grinders?
Answer: Angle Grinders are basically handheld power tools that can be conveniently used for carrying out a broad array of metal construction tasks including cutting, deburring, grinding, polishing, finishing, etc.
And to use your wire wheels on your angle grinder, all you'll need is a set of flange for attachment. A flange is just a collar or rim that enables the attachment of other equipment securely.
Benched grinders, on the other hand, are a type of grinding machine that is set up on benchtops. They are the larger and more stationary version similar to a grinder which is used for driving abrasive wheels.
In order to add your wheels to your benched grinders, simply detach the grinder's exterior guard and then take off the shaft. You'll then require two flanges- a thick and a thin. The thicker one will be for attaching the wire wheel to your tool while the other thinner one will be attaching to the nut.
5. What To Do If The Brushes Of The Wire Wheels Seem To Get Blunt?
Answer: This is quite the expected scenario which is likely to happen when the wheels have been used for a while now. In this case, if they do seem blunter and ineffective than before, simply reversing the rotation of your attachment tool ought to do the trick.
Not only will the more unused side of the wire bristles be used, but the ends will also be sharpened too! Hence, your wheels should be back to its original glorious and effective performance in no time!
6. Are Wire Wheels Only Capable Of Removing Rust From Metals?
Answer: Luckily, the answer is no. This is because these power-wheels can not only effectively remove rust, but will also ensure the removal of old paint layers and other contaminants. It can thus be a great equipment to get your metal surface all prepped up and clean for its new coat of paint, glue, rubber, etc.
You will also be able to roughen up wood surfaces to add texture to them using these versatile wheels.
For newbies, this may clearly not be the most common tool that we expect everyone to know as they do about smartphones, PCs, laptops, etc. But as we just saw, a little brainstorming can go a long way.
We are so concerned about the easier and the cheaper options of getting rid of rust, that sometimes, the matter of safety, convenience, effectiveness, efficiency, etc. are often overlooked.
The best wire wheel for rust removal will surely be a great tool for you as it’ll mean that you no longer have to throw away your precious metal belongings.
These tools are not only super-easy and safe to use as no chemicals are involved, but they are also incredibly affordable and you probably have a drill lying around somewhere.
Hopefully, you are all set now to salvage all those precious objects that probably had no future as they were lying there heavily corroded.